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02 2013 EDUCATION Raw materials production - Abbau fester mineralischer Rohstoffe im untertägigen Bergbau
Tudeshki, H.
Institute of Mining | TU Clausthal | Germany
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EDUCATION
Einführung in die Rohstoffgewinnung
Abbau fester mineralischer Rohstoffe im untertägigen Bergbau
von Univ.-Prof. Dr.-Ing. habil. H. Tudeshki Nach dem bereits im Rahmen der Weiterbildung der Institut für Bergbau | TU Clausthal | Deutschland AMS-Ausgabe 01/2013 mit der Einführung in die Rohstoffgewinnung begonnen wurde, erfolgt nun die Fortführung der verschiedenen Abbauverfahren des Themas „Abbau fester mineralischer Rohstoffe im untertägigen Bergbau.
Abbauverfahren mit pfeilerartiger Bauweise
Gewöhnlicher Pfeilerbau
Auch bei den Abbauverfahren mit pfeilerartiger Bauweise kann zwischen Verfahren bei flacher und steiler Lagerung unterschieden werden. Liegt eine Lagerstätte in flacher Lagerung vor, so kann hier der so genannte gewöhnliche Pfeilerbau eingesetzt werden, bei dem die einzelnen Pfeiler nebeneinander liegen. In steiler Lagerung wird hingegen der Teilsohlenpfeilerbau angewendet, bei dem die Pfeiler übereinander angeordnet sind. Diese beiden Abbauverfahren werden im Folgenden näher beschrieben.
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Es existieren vielfältige Variationen des Pfeilerbaus, die sich im Wesentlichen hinsichtlich der Lage, des Verlaufes und des Abstandes der Pfeilerstrecken untereinander unterscheiden. Durch den Abstand der Pfeilerstrecken wird zwangsläufig die Pfeilerfläche festgelegt. Ein weiteres Unterscheidungskriterium ist die Dachbehandlung, die entweder in Form des Bruchbaus oder in Form des Versatzbaus erfolgen kann
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Die Pfeiler können dabei, wie in Abbildung 1 dargestellt, eine quadratische Grundfläche aufweisen. Allerdings sind auch rechteckige Grundflächen durchaus üblich. Die Abbildung 2 zeigt einen Überblick über die beim Pfeilerbau notwendigen Arbeitsprozesse.
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Abb. 1: Prinzip des Pfeilerbaus
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EDUCATION
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Die Pfeilerstrecken werden in einem oder mehreren Arbeitsgängen in ihrer Gesamtmächtigkeit aufgefahren. Zur Stabilisierung des Hangenden werden die Pfeiler stehen gelassen. Für das Auffahren der Pfeilerstrecken kommen Bohrwagen zum Einsatz, die die Lagerstätte horizontal oder vertikal abbohren. Das gesprengte Haufwerk wird mittels mobiler Technik abgefördert.
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Im bergmännischen Sprachgebrauch muss zwischen Pfeilern und Festen unterschieden werden. Von ihrer Funktion sind beide im Wesentlichen identisch, sie unterscheiden sich nur dadurch, dass Festen dauerhaft stehengelassen werden, während Pfeiler nachträglich abgebaut werden. Nach Art der Abbauführung ist der Pfeilerbau immer ein Rückbau. Bei der Vorrichtung werden die Pfeilerstrecken bis zu den Abbaugrenzen vorgetrieben. Das spätere Abbauen der Pfeiler wird im Rückbau realisiert. Das Zurückbauen der Pfeiler findet meist an vier bis sechs benachbarten Pfeilern gleichzeitig statt. Grundsätzlich wird darauf geachtet, dass sich eine im Ganzen möglichst grade Front des Bruches am Alten Mann ausbildet. Die Bruchfront kann diagonal oder parallel zu den Pfeilerstrecken voranschreiten (Abbildung 3).
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Abb. 2: Pfeilerbau bei flacher Lagerung [2]
Für den Abbau der Pfeiler gibt es eine Vielzahl von Vorgehensweisen. An dieser Stelle soll nur eine der Möglichkeiten erwähnt werden. Wird eine diagonale Bruchfront angestrebt, so kommt meist die so genannte Open End-Methode zum Einsatz. Der Pfeiler wird hierbei in mehreren geraden Stößen, mit der Reihenfolge entsprechend der Zahlen in Abbildung 4, hereingewonnen. Beim Hereingewinnen der Stöße wird ein Unterstützungsausbau (Bruchkästen) eingebracht, der wiederum geraubt wird, wenn der Stoß bis zum Alten Mann vorgedrungen ist. Ein vollständiger Abbau des Pfeilers ist nicht möglich. Die nachstehende Abbildung 5 zeigt einen Pfeilerbau mit länglichen rechteckigen Pfeilern, bei dem Versatzbau angewandt wird. Die einzelnen Phasen des Abbaus sind in der Abbildung von rechts nach links dargestellt. Bei diesem Verfahren werden zunächst Lagerstättenstreifen einer bestimmten Breite abgebaut. Zwischen den einzelnen Abbauen bleiben Pfeiler stehen. Nachdem der Stoß abgebaut wurde, wird er mit Versatz verfüllt. In einem weiteren Arbeitsschritt können nach dem Aushärten des Versatzes die Pfeiler in gleicher Art abgebaut werden. Die Versatzbereiche funktionieren in diesem Fall als das Hangende abstützende Feste.
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EDUCATION Abb. 4: Abbau der Pfeiler beim Pfeilerbruchbau
Abb. 3: Prinzip des Pfeilerbruchbaus
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Abb. 5: Pfeilerbau mit rechteckigen Pfeilern
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EDUCATION Das Abbauverfahren ist aufgrund der hohen Kosten für das Einbringen des Versatzes nur für hochwertige Lagerstätten geeignet, bei denen die Abbauverluste durch die stehen gelassenen Festen möglichst gering gehalten werden sollen.
Teilsohlenpfeilbau Bei steilstehenden Lagerstätten unterschiedlicher Mächtigkeit ist der Teilsohlenpfeilerbau sehr verbreitet. Im Hinblick auf die Dachbehandlung ist der Teilsohlenbruchbau die am häufigsten auftretende Variante. Aber auch ein Einsatz von Versatz ist möglich.
Die Vorrichtung für dieses Abbauverfahren beginnt mit dem Auffahren und Verbinden zweier Teilsohlen ausgehend von einer Wendelstrecke. Der übliche Abstand zweier Teilsohlen liegt bei 5 bis 15 m und ist abhängig von den geologischen Gegebenheiten. Die zwischen den Teilsohlen gelegenen Pfeiler werden im Rückbau durch Bohr- und Sprengarbeit hereingewonnen. Die Pfeiler zwischen den Teilsohlen werden mittels Bohrwagen über ihre gesamte Mächtigkeit abgebohrt und im Anschluss gesprengt. Das so entstandene Haufwerk kann über die darunter liegende Teilsohle abgezogen werden. Abb. 6: Teilsohlenbruchbau [2]
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EDUCATION Da das Gestein durch den Einfluss der Schwerkraft nachbricht, ist es wichtig, dass das Nebengestein eine ausreichende Standfestigkeit aufweist, damit zusätzliche Verunreinigungen des Erzes und damit einhergehend eine Verdünnung vermieden werden kann.
Abbauverfahren mit kammerartiger Bauweise
Örterbau
Bei den Abbauverfahren dieser Bauweise werden kammerartige Abbauhohlräume geschaffen. Das umliegende Gebirge wird durch stehen gelassene Festen abgestützt. Durch diese Festen, die nicht nachträglich abgebaut werden, entstehen unvermeidliche Abbauverluste. Die auftretenden Abbauverluste können wie in Abbildung 7 dargestellt berechnet werden. Dabei wird jeder Feste eine identische Fläche zugeordnet. Das Verhältnis der Festenfläche zu dieser Fläche beschreibt die auftretenden Abbauverluste.
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Diese Bauform ist gekennzeichnet durch das Auffahren von lang gestreckten Abbauräumen mit streckenähnlichen Abmessungen, so genannte Örter. Die Breite der Örter richtet sich nach der Standfestigkeit des Gebirges, die Höhe ist meist an die Mächtigkeit der Lagerstätte angepasst. Die einzelnen Örter verlaufen parallel zueinander und kreuzen sich rechtwinklig oder schräg.
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Das Wertmineral wird mittels Bohr- und Sprengarbeit gewonnen und mit mobilen Transportgeräten nach übertage gefördert. Der Örterbau ist in Deutschland im Kalisalzbergbau der flachen Lagerung im WerraFulda-Gebiet anzutreffen. Hierbei weisen die Örter eine Breite von 16 m und eine Höhe von 4 m auf. Die quadratischen Festen haben eine Kantenlänge von 26 m. Die nachstehende Abbildung 9 zeigt das Schema eines Örterbau im Kalisalzbergwerk Hattorf. Die Abbaufront verläuft pfeilförmig. Zum Auffahren der Örter wird zunächst ein 5 m breites Ort mit Einbruch auf Großbohrloch (∅ 280 mm) hergestellt. Im zweiten Arbeitsgang wird das Ort auf die endgültige Breite von 16 m erweitert.
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Die Abbauverluste bei den hier angenommenen Dimensionen für die Festen und Örter belaufen sich auf rund 38%.
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Die Festen müssen umso größer dimensioniert werden, je tiefer der Abbau liegt und desto weniger standfest das umgebende Gebirge ist. Von den weltweit angewendeten Abbauverfahren mit kammerartiger Bauweise sollen im Folgenden der Örter- und Kammerbau sowie der Weitungsbau näher betrachtet werden.
Im internationalen Raum wird der Örterbau häufig in untertägigen Gewinnung von Steinkohle (USA) eingesetzt.
Abb. 7: Berechnung der Abbauverluste durch Festen
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EDUCATION
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Abb. 8: Örterbau
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Beim Kammerbau werden regelmäßig geformte, meist rechteckige Abbauräume aufgefahren. Die Abmessungen von Kammern sind deutlich größer als die von Örtern, zudem werden Kammern in mehr als einem Arbeitsgang hergestellt. Im Vergleich zu einer Weitung sind die Abmessungen der Kammern vor Beginn des Abbaus festgelegt. Die Kammern sind umgeben von Festen oder Pfeiler, die die Standsicherheit des Abbauhohlraumes sicherstellen. Im Hinblick auf die Dachbehandlung ist beim Kammerbau sowohl der Festenbau als auch der Versatzoder Bruchbau anzutreffen. Abbildung 10 zeigt einen Kammerbau auf dem Steinsalzbergwerk Borth.
Abb. 9: Schema eines Örterbaus, Kalisalzbergwerk Hattorf [1]
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EDUCATION Die Kammern werden zunächst mit einem Marietta Miner mit einer Mächtigkeit von 2,75 m und einer Breite von rund 8 m aufgefahren. Zur Absicherung der Kammer werden Firstanker gesetzt. In einem zweiten Arbeitsschritt wird diese Kammer mit dem Marietta Miner in zwei weiteren Schnitten auf eine Breite von 20 m erweitert. In der Abbildung in grün dargestellt sind das Schneiden des Strossenkeils und damit die Erweiterung der Kammer auf eine Höhe von 17,25 m. Ist der Strossenkeil erstellt kann mit dem Strossen begonnen werden. Hierzu werden Strossenbohrwagen eingesetzt, die das Wertmineral in der Kammer vertikal abbohren. Nachdem das Salz gesprengt wurde, kann es mittels mobiler Technik aus der Kammer transportiert werden.
Weitungsbau Im Gegensatz zum Kammerbau ist der Weitungsbau durch unregelmäßig geformte Abbauräume gekennzeichnet. Weitungen sind Abbauräume, deren Abmessungen durch die Struktur und Standfestigkeit der Lagerstätte und des Nebengesteines abhängig sind und daher zu Beginn des Abbaus nicht exakt festgelegt werden können. Aus Sicherheitsgründen dürfen Weitungen nicht betreten
Abb. 10: Kammerbau auf dem Steinsalzbergwerk Borth
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werden. Der Verhieb findet somit auch nicht in der Weitung statt, sondern von horizontalen Strecken am Rand der Weitung aus. Die Weitung wird von Teilsohlen aus durch Bohren und Sprengen hergestellt. Dabei sind fächerförmig abgebohrte Sprengbohrlöcher mit einer Länge von 40 m und mehr die Regel. Der Abstand der Teilsohlen richtet sich nach der maximal möglichen Bohrlochlänge und der dabei erreichbaren Zielgenauigkeit. Der Weitungsbau tritt in den Varianten mit und ohne Versatz auf.
Abbauverfahren mit blockartiger Bauweise
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Bei den Abbauverfahren mit blockartiger Bauweise werden quaderförmige Lagerstättenteile in Angriff genommen. Voraussetzung für dieses Verfahren ist eine in alle Richtungen ausgedehnte Lagerstätte mit mäßiger Standfestigkeit. Im Hinblick auf die Dachbehandlung ist der Blockbruchbau die wichtigste Variante. Die nachstehende Abbildung 12 zeigt das Prinzip eines Blockbruchbaus.
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EDUCATION Abb. 11: Weitungsbau [2]
Die Ausrichtungsgrubenbaue um- und unterfahren die Lagerstätte und berauben damit dieser ihren Widerlagern. Das Wertmineral innerhalb des unterfahrenen Blockes bricht infolge der Schwerkraft von selbst herein. Beim Unterschneiden des Blockes werden Fördertrichter angelegt, durch die ein Abziehen des Minerals möglich ist. Der Vorteil des Blockbruchbaus sind die sehr niedrigen Gewinnungskosten bei einer sehr hohen Leistung. Entwickelt wurde das Verfahren im Norden der USA. In den Wintermonaten, in denen ein Abtransport des abgebauten Erzes aufgrund der zugefrorenen Seen nicht möglich war, wurden die Umfahrungen und Unterfahrungen mehrer Blöcke vorgenommen. In den Sommermonaten konnte dann das Erz aus den Blöcken in großen Mengen entnommen werden.
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Abb. 12: Blockbruchbau [2]
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EDUCATION Bibliography
[22] Thyssen-Schachtbau: Thyssenschachtbau-Report 2004
[1]
Reuther, E.-U.: Lehrbuch der Bergbaukunde
[2]
Atlas Copco: Underground Mining Methods – Mining Methods case studies, a technical reference edition,
[3]
Fotomaterial: http://web.uct.ac.za/depts/geolsci/dlr/hons2000/
[4]
Bundesanstalt für Geowissenschaften und Rohstoffe: Verschiedene Artikel und Publikationen
[5]
GibGas – Fahren mit Erdgas: Internetpräsenz http://www.gibgas.de/german/fakten/naturstoff_erdgas.html
[6]
Bay. Sand- und Kiesindustrie: Schriftenreihe der bayrischen Sand- und Kiesindustrie, Heft 2
[7]
Bundesanstalt für Geowissenschaften und Rohstoffe: Dr. Michael Kosinowski, Tendenzen auf dem Rohstoffmarkteine Analyse der BGR
[8]
Deutsches nationales Komitee des Weltenergierates: Energie für Germany – Fakten, Perspektiven und Positionen im globalen Kontext 2002
[9]
DEBRIV: Arbeitsgemeinschaft Energiebilanzen 2003
[10] World of Mining Surface and Underground: Die Verfügbarkeit von Rohstoffen – insbesondere von fossilen Energieträgern, 04/2004 [11] Verein der Kohlenimporteure: Jahresbericht 2003 [12] Bundesanstalt für Geowissenschaften und Rohstoffe: Rohstoffwirtschaftliche Studie, 2002 [13] DEBRIV: http://www.debriv.de/zahlen/folien/grafik09.pdf [14] Statistik der Kohlenwirtschaft e.V.: http://www.kohlenstatistik.de/ftp/BK-WELT.XLS [15] Wirtschaftsvereinigung Bergbau: Nachfrage und Absatz von Steinkohle, http://www.wv-bergbau.de/ [16] USGS – United States Geological Survey: Iron Ore – Statistics and Information, Mineral Commodity Summaries 2005 [17] International Aluminium Institute: Aluminium production www.world-aluminium.org/ production/ [18] Wirtschaftsvereinigung Metalle: Metallstatistik 2003
[23] Thyssen-Schachtbau: TS Schachtbau und Bohren, Internetpräsenz http://www.schachtbau-bergbau.de/ [24] RKK-Soilfreeze Technology: About Ground Freezing, www.cryocell.com/AboutGF.html [25] Deilmann-Haniel: Herstellung einer Wetterbohrung auf der Schachtanlage Heinrich Robert, Zeitschrift Unserer Betrieb, April 1992, [26] Herrenknecht: Datenblatt VSM 8000 Shaft sinking machine 11/2004 [27] Orica: Internetpräsenz der Firma Orica, http://www.oricaminingservices.com [28] DBT: Internetpräsenz der Firma DBT, www.dbt.de, Broschüre DBT Diesel FBR-15 Coal Hauler [29] Atlas Copco: Internetpräsenz der Firma Atlas Copco, Photoarchiv, http://www.atlascopco.com [30] Kali und Salz: Internetpräsenz der Firma K+S, Pressefotos, http://www.k-plus-s.com [31] Deutsche Steinkohle AG: Internetpräsenz der Firma DSK, Bildarchiv http://www.deutsche-steinkohle.de [32] Betek: Internetpräsenz der Firma Betek http://www.betek.de/ [33] Eickhoff: Bildmaterial der Firma Eikhoff Bergbautechnik GmbH [34] Wirth: Internetpräsenz der Firma Wirt, http://www.wirth-europe.com, Broschüre RM T 1.24 [35] Parallelgraphics: Bildmaterial der Firma Parallelgraphics, http://www.parallelgraphics.com [36] Voest Alpine Bergtechnik: Internetpräsenz der Firma Voest Alpine Bergtechnik http://www.vab.sandvik.com, Bildmaterial ASVA [37] Herrenknecht: Internetpräsenz der Firma Herrenknecht http://www.herrenknecht.com [38] Geo Kompakt: Geo Kompakt, Nr. 1, 2004, Die Geburt der Erde, Vom Werden und Vergehen der Gesteine, S. 89 [39] Steinkohle-Portal: Internetpräsenz http://www.steinkohle-portal.de
[19] Volker Lukas: Kali- und Steinsalz in Germany, Akademie der Geowissenschaften, Hannover, 2002, Veröffentlichung 20, (2002), S. 54-62
[40] DBT: Internetpräsenz der Firma DBT, www.dbt.de
[20] IG BCE: Bericht I/2004, Kalibergbau und weiterer Nichtkohlenbergbau
[42] Mining Magazine: Mining Magazine, Ausgabe Februar 2005 http://www.grundwasser-online.de
[21] Deilmann-Haniel: Internetpräsenz der Firma DeilmannHaniel, http://www.dh-ms.com
[41] Halbach & Braun: Internetpräsenz der Firma Halbach und Braun, http://www.halbach-braun.de/
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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Issue 02 | 2013
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Design, Replacement, and Power Measurements for the Long Distance Pipe Conveyor Belt at Western Arch Coal Skyline Mine, USA Dr. Andrey Minkin, Dr. Andreas Jungk, Thomas Hontscha ContiTech CBG | Northeim | Germany
This paper describes the design and replacement of the Pipe Conveyor belt for the Arch Western Coal Skyline Mine Pipe Conveyor BC-08 near Helper, Utah. Furthermore, results of power measurements at the time of commissioning and after break in are presented. The Skyline Pipe Conveyor BC-8 is located approximately 3500 m above sea level. It has a center distance of C-C=3414 m and an elevation drop of ΔH = -172 m. This Pipe Conveyor, with an outer (idler) diameter of DO ≈ Ø452 mm, has 22 horizontal and 45 vertical “sharp” curves. The Pipe Conveyor transports coal at the mass flow Im ≈ 1270 mtph (1400 stph) downhill from the mine site to the mine’s train loading facilities. Before ThyssenKrupp Robins, Inc., Denver, CO (TKRI) was contracted to build the Pipe Conveyor, trucks were used to transport coal. Transporting coal by Pipe Conveyor significantly improved the efficiency for Maintenance and Operations by a factor of 9 when compared with trucking [1]. The turnkey project included the design, delivery, installation and commissioning of the Pipe Conveyor belt.
Project details Upon initial installation, the Skyline Mine Overland Pipe Conveyor BC-8 was the highest capacity and second longest steel cord Pipe Conveyor in the World. Since 1993, additional Pipe Conveyors that are longer and of higher capacity, have been built. The featured Pipe Conveyor is
significant due to its high number of horizontal and vertical “sharp” curves and remains recognized, worldwide, as a remarkable material handling solution. (Figure 1). The routing follows the natural terrain as it traverses through Eccles Canyon while transporting approx. Im ≈ 1270 mtph (1400 stph) of coal at 4.18 m/s. Figure 2 shows the drive and take-up configuration.
Fig. 1: Pipe Conveyor belt routing, seen from the head end (left) and tail end (right)
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TRANSFER OF TECHNOLOGY The main technical details of BC-8 as described in [1] are below: • • • • • • • •
• • • • • •
Pipe Conveyor Belt: St1000 8+6, width 1600 mm Outer (idler) Diameter DO ≈ Ø 452 mm (17.8“) 22 horizontal und 45 vertical curves (min. Curve Radius rmin = 365 m (1200 ft)) Center Distance: C-C = 3414 m; the steepest inclination α = 11° Gravity Take-up at Head Load / Return Idlers Spacing on Straight: pl ≈ 2,27 m (7 ft 6 inch) / pr ≈ 4,57 m (15 ft) Load / Return Idlers Spacing in Curves: plc ≈ 1,83 m (6 ft)/ prc ≈ 3,66 m (6 ft) Shunt DC-Motors with Drive Power: 2 x 299 kW (2 x 400 HP) at Tail + 1 x 299 kW (2 x 400 HP) at Head Overload: 200% for 2 Minutes Max. Belt Speed: vmax = 4,2 m/s; (827 fpm) Max. Fill Ratio: ηF ≈ 0,7 Design Mass Flow: Im ≈ 1270 mtph (1400stph) Material: Crushed Coal (maximum size dKmax ≈ 51 mm or 2 inch) Temperature Interval: -40 °C (40°F)≤ T ≤ +38 °C (+100°F) Downhill Conveyor System: Difference in height Tail → Head ΔH ≈ -172 m (-564 ft)
The layout of Pipe Conveyor for BC-8 follows the terrain’s natural contour in order to minimize the conveyor’s impact to the environment. When the mine decided to replace the old belt, ContiTech was challenged to design the new pipe belt to be suitable to the existing routing of BC-8.
ContiTech Conveyor Belt Group from Germany received a purchase order to design, manufacture, supply and replace the existing belt and commission the new Pipe Conveyor belt. For the customer, the extensive experience of ContiTech in designing, manufacturing and installing a unique conveyor belt in very demanding conditions, was a deciding factor for awarding the order to ContiTech. Because ContiTech was not involved in the design and the installation of the initial belt, ContiTech teamed up with two partners, who already had the expertise in handling this conveyor system. The first partner was the supplier of the original equipment; ThyssenKrupp Robins, Inc., Denver, CO (TKRI). TKRI provided assistance in the planning of the belt replacement, the commissioning of the new belt and technical support for the necessary system maintenance to ensure that the new belt would fit into the existing structure. The second team member was Applied Industrial Technologies (AIT) from Salt Lake City, Utah, who knew the system and the conditions prevailing, on site, from various maintenance activities. AIT was responsible for all preparatory work for pulling the new belt, the belt splices and personnel during commissioning.
Design consideration for the new Pipe Conveyor belt Pipe Conveyors are primarily used where the key characteristics of the Pipe Conveyor can be fully utilized; they are: •
Due to the specific idler configuration and the tubular shape of a pipe belt, the Pipe Conveyor may follow the natural terrain more easily than a standard troughed conveyor. Pipe Conveyors allow small curve radii and steep inclination angles.
•
The suitability of a Pipe Conveyor for 3D-curve routings often helps to reduce the number of transfer points reducing earthwork. Also, the reduced number of mechanical components (drives) and transfer chutes minimized maintenance efforts and costs and the fewer number of transfer points increases the belt life.
•
Conveyed material is fully enclosed by a Pipe Conveyor belt (Figure 3). Therefore, the environment is protected from the bulk material and the conveyed material is protected from the elements like rain, snow or wind.
•
Minimum spillage.
Additionally, ContiTech had to minimize the downtime during the belt installation and commissioning to reduce loss of production.
Tail 2 Motors
v
Head 1 Motor
Gravity Take-up Fig. 2: Drive and take-up configuration of BC-8
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TRANSFER OF TECHNOLOGY
Fig. 3: Setup of the Pipe Conveyor (left) vs. a standard (troughed) conveyor, right
Pipe Conveyors are a specialty product for the “right” application and offer solutions conventional conveyors cannot provide. If a Pipe Conveyor is compared against a troughed conveyor for an “ordinary” setting certain disadvantages become evident: •
Higher design, manufacturing and installation costs.
•
Higher energy consumption due to pipe forming forces, friction in the belt overlap and a higher number of idlers.
•
Lower capacities because of smaller cross sectional load area in relation to the belt width.
•
Significantly more effort and specific knowledge of the system are necessary for the commissioning of a Pipe Conveyor.
For Pipe Conveyors, the capacity, bulk density, maximum material lump size and the belt speed determine the pipe diameter and therefore the belt width, which determine application limits, in principal. Moreover, the safe operation of a Pipe Conveyor belt is determined by the required transversal stiffness of the belt, as the most important design parameter for the application. The transversal stiffness (i.e. the transversal flexibility) and the bending characteristic of the pipe belt depend on the application limits such as the required belt overlap, nominal belt strength and radii of horizontal and vertical curves in conjunction with local belt tensions. The belt’s very high transversal stiffness results in high forming forces and results in higher energy consumption due to increased running resistances. The running resistances result from intensive contact between the belt and idlers, friction in the belt overlap and the tendency of the belt to open between idler panels. If the transversal stiffness is too low, the belt buckles in curves or may collapse entirely. Hence, an optimized pipe belt design requires sufficient transversal stiffness for maintaining the pipe form over the entire life time, as well as to provide the cross-sectional area that is necessary to ensure desired capacity. That is why it is very important that the cross-sectional area of a Pipe Conveyor belt, as provided for the conveyed material, is not reduced by forces acting on the belt, especially in vertical and horizontal curves. On the other hand, the
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stiffness of the Pipe Conveyor belt should be sufficiently optimized in a way that it does not induce unacceptable levels of resistance to motion as a result of increased forming forces applied to the idlers. For Pipe Conveyor applications (Figure 3), the idlers are usually fastened in a hexagonal form to the carrying panel. The configuration of idler stations is extremely important. A larger distance between idler stations leads to more bulging of the belt and the overlap opens and creates additional stresses at the following idler station as the belt edges are forced into the overlap and the pipe is closed again. Therefore, the forming force is increased. As shown in Figure 4 for Pipe Conveyor applications, it is very important to consider the influence of the conveyor routing on belt tracking. The overlap area in the perimeter of the pipe conveyor belt forms the belt section with the highest mass, as well as the highest concentration of tension member. When being moved through curves the belt therefore tries to assume a condition of lowest tension by turning the overlap towards the inner side of the curve. When loaded, the material stabilizes the pipe belt by keeping the overlap in the “12-o’clock-position”. The balance point is below the center of the pipe and the belt is in a balanced position. When the overlap is in the 12o’clock-position, however, the unloaded belt is unstable due to the weight distribution, with most of the belt weight positioned on top of the pipe (Figure 5). This condition creates the tendency for the belt to rotate. The initially installed Pipe Conveyor belt St1000 (1000 N/mm), 1600 mm width, covers 9 mm + 6 mm had a layer of transverse fabric reinforcement (breaker) above and below the steel cables, which were separated by a rubber layer from the steel cords [1]. Such design is very beneficial in keeping the overlap in the 12-o’clock-position and provides good belt guidance in curves. Nevertheless, because of the large number of “sharp” horizontal and vertical curves and based on the experience with the initially installed Pipe Conveyor belt of a third party manufacturer, ContiTech designed the new Pipe Conveyor belt. The new belt utilized a combination of
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TRANSFER OF TECHNOLOGY
Fig. 5: Center of Gravity, Loaded and Unloaded Belt
Fig. 4: Tracking of a Pipe Conveyor belt in curves
fabric and steel transverse reinforcements: Rollgurt 1000 S-K2, 8T:6S, 1600 mm width, ContiExtra with a nominal breaking strength of kN = 1000 N/mm. Special attention was given to the design of edge areas of the new Pipe Conveyor belt and to the correct selection of the rubber compound. The new design allows a safe operation at a min. curve radius Rmin = 365 m (1200 ft) and a more stable tubular shape, so the possibility that the belt can collapse in the future is greatly reduced. The selected rubber compound ContiExtra works at the temperature of T = -40 °C (-40°F) even with strong deformations resulting from the conveyor profile and the pipe forming. The final tests, including analyzing and establishing the forming forces, confirmation of the tubular shape and form of overlap, and defining the behavior of the pipe belt sample in a curve at the temperature range of +38°C (+100°F) to -40 °C (-40°F), were conducted at ContiTech test facilities in Northeim, Germany. The considerations, as stated above, show that the most important parameter is a sufficient contact length and contact force between the belt and the idlers, in order to guide the belt through a curved conveyor. This can only be achieved by a belt design with optimized transversal stiffness and flexibility. Hence, it is evident that a Pipe Conveyor belt is designed and specified in order to gain an optimized solution for the specific application cases with respect to tracking capabilities, as well as power demand. Consequently, the design of a Pipe Conveyor and of a Pipe Conveyor belt is significantly different from the common design of a Standard belt conveyor and of a belt
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that is used for Troughed conveyor applications. That is why OEMs and belt manufacturers should work side by side to optimize the Pipe Conveyor in detail.
Belt replacement procedure When a new conveyor belt has to be installed as a retrofit, upgrade or replacement of an existing transport method, the impact of the conveyor system downtime and the resultant lost production should be minimized. After analysing the terrain and routing and in consultation with the customer, ContiTech decided to pre-splice and pull in the new belt from behind of the BC-8 Head Station. Similar to the KPC-project [3], the new pipe belt was connected to the existing old belt via a temporary (dummy) splice. As the new belt was pulled into the system, the old belt was pulled out. This temporary splice, however, needs to be a 100%-functional splice for the occasions when the system needs to be restarted at normal operating parameters, before the belt replacement is completed. Figure 6 shows the principle of reeving the belt prior to the belt pulling. The access to the idler frames and the Pipe Conveyor belt was very limited because the conveyor system is mainly installed in fully covered trusses and galleries. The belt was shipped in eight reels, a total of 6940 m. The pipe belt was pulled from the belt reel through the splice shed and reefed in approximately 75 layers, resulting in a belt stack of approx. 1.5 m height (Figure 7, left). In order to reduce friction forces between the layers while reeving and pulling the belt, each belt layer was separated by a layer of sand. Reeve tubes were installed to protect the
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TRANSFER OF TECHNOLOGY Fig. 6: Scheme of the belt reeving
belt from a sharp bend where the belt folded back on itself (Figure 7, right). For this pipe belt, ContiTech provided a special splice design that differs dramatically from designs for standard troughed belts. Before starting to pull in the new pipe belt, ContiTech estimated resistances to motion and checked if the installed total drive power was sufficient to pull the final section of the new pipe belt onto the system. Figures 8 and 9 give an overview of the setup for the belt pulling into the conveyor system. At creep speed and using the installed DC-drives, the old belt was pulled out while the new belt was fed into the return strand of the Pipe Conveyor structure from the stack of reeved belting. In order to access the head pulley of the conveying system a lift of approximately 12 m (39’), consisting of inaccessible terrain, was negotiated from the laydown area to the head end. A temporary conveyor of approximately 52 m (170’) in length was installed (Figures 8 & 9) to reduce friction and to guide the new belt towards the feeding point.
With this setup, the belt was installed quite smoothly within 5 days. The old belt was spooled on a reel by a powered winder. After the pulling was completed, the belt was closed to form an endless belt with the final splice.
Commissioning After the installation had been finished, the commissioning of the conveyor system started. The plan of the project team was: •
Commissioning of the unloaded conveyor system,
•
Make all necessary adjustments and reassemble all dismantled structures at the head end,
•
Commissioning of the system with progressively increased speed and filling ratio
Since the behaviour of the belt during the pulling procedure was very positive. The overlap was oriented in the 12-o’clock and 6-o’clock position in the carry and
Fig. 7: Reeving of the belt with a winch (left) and installed tubes in belt folds (right)
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TRANSFER OF TECHNOLOGY Fig. 8: Scheme of Pulling the Belt into the Conveyor Structure
return strand, respectively, at almost every position. Consequently, no preparative work was required prior to starting the conveyor. After tensioning and empty operation for several revolutions, the belt ran very stable with the overlap at 6- and 12-o’clock positions at every speed and had a contact to all six idlers present in the panel, as pictured in Figure 10. Therefore, the belt made the full cross-section of the system available for coal transport, as intended. In addition, the overlap remained tightly closed between the idler stations. Since the belt approached the pulleys without any problems, no changes to the system, regarding belt tracking, were necessary and the efforts for the commissioning of the conveyor were minimized. During the following step of the commissioning, the belt was loaded at several fill ratios and speeds.
Power measurements ContiTech performed power measurements several times; during the commissioning, after 13 days (during the break-in period), and after the break-in period was over in the summer and winter. The idea was to collect information concerning friction forces in the conveyor system at different times during the operation period. This helps OEMs to design Pipe Conveyors more efficiently. For this purpose power readings were taken from the system’s inverters at the mine site (Figure 11). For a Shunt DC-Motor (Figure 12), the Electrical Power Consumption PE can be calculated as: PE = IARM ∙ UARM
Fig. 9: Pulling the new pipe belt into the conveyor structure
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TRANSFER OF TECHNOLOGY
The Electrical Power Efficiency ηE is estimated as: • ηE = PMn /PEn = PMn /(IARMn ∙ UARMn ), • • • • • • • •
• • • •
where: PI =299 kW (400 HP) – nominal Mechanical Power of Motor according to the motor label PEn = IARMn ∙ UARMn = (626 A ∙ 500 V)/1000 = 313 kW (420 HP) – nominal Electrical Power of Motor IARMn = 626 A – nominal current according to the motor label UARMn = 500 V – nominal voltage according to the motor label ηE =0.96 – Electrical Power Efficiency at rated frequency The Mechanical Power PM is: PM = PE ∙ ηE The power required by a belt conveyor PD that has to be transmitted to the conveyor belt by drive pulleys at the rated frequency is calculated as: PD = PM ∙ ηM = PE ∙ ηE ∙ ηM , where the Mechanical Power Efficiency: ηM ≈ 0.97 The power required by a belt conveyor PD from the motional resistance F and the belt speed: PD = F ∙ v
Fig. 10: The new belt contacts all idlers in the carry strand (left) as well as the return strand (right)
Knowing the value of the power required by a belt conveyor PD and the belt speed v, the motional resistance F and, consequently, the DIN-f factor can be calculated [7, 8]. For this purpose, specific software like BeltCon (ContiTech), BeltAnalyst (Overland Conveyor Company Inc.), or similar design software can be helpful. Fig. 12: Scheme of a Shunt DC-Motor [6]
Fig. 11: Display of the system’s inverters
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TRANSFER OF TECHNOLOGY Figure 13 shows the results of the measured electrical power consumption in % of the nominal electrical power of motor (i.e. PE / PEn [%]) dependent on the belt speed, in % of maximum belt speed (i.e. v / vmax [%]) without material. These measurements were performed with the help of inverters of the BC-8-Pipe Conveyor (Figure 11) during commissioning and after the break-in period. Additional power readings were performed in summer (T ≈ +15°C (59°F)) and in winter (T ≈ -14°C (7°F)), after the break-in period was over, to investigate the temperature influence of friction in the system and the transversal rigidity of the pipe belt. The ContiTech experience shows that the total breakin period can take up to several months when the belt is running. When the break-in period is over, the measured power consumption level remains constant for several months during the same season of the year. Usually the system is operated at 80% of the maximum belt speed. Other speeds, as shown in Figure 13, are commissioning presets. The power demand of the system follows the belt speed almost linearly; therefore the resistance to motion in the system is not influenced by the belt speed. When the new belt was operated for the first time, without material, during the initial commissioning of the system, approximately 90% of nameplate motor power was used when running at 90% at full speed.
Figure 14 shows the power consumption during commissioning, after commissioning and after the breakin period when loaded in summer. All these measurements were made at temperatures of approximately +15°C (59°F), to avoid the temperature influence on the results. During commissioning, with material, the system’s power demand in the loaded condition was approximately 75% of the installed motor power. After nearly two weeks of operation, this value had reduced by approximetly11%. After the break-in period, the power consumption dropped by another 18%. Consequently, the difference in the power consumption between the commissioning time and the time after break-in is approximately 30%. As mentioned previously, the high transversal rigidity of the pipe belt reduces over time. This is a result of the belt running and adapting to the conveyor system over several months of initial operation. In the winter, the belt continues to operate with sufficient safety factors, showing the highest belt tension at the tail pulley in the return strand.
Fig. 13: Power consumption during commissioning and after the break-in period in summer and in winter
After the break-in period was over, the power consumption dropped by approximately 30% during the same warm season. This behavior is a result of the transversal rigidity of the pipe belt and its high forming forces at the beginning of the break-in period. The power consumption reduces as the belt adapts to the conveyor system. Furthermore, from Figure 13 it is evident that the temperature has a very strong influence (over 20%) on power consumption. This can be explained by the increase of the transversal rigidity of the Pipe Conveyor belt (rubber becomes stiff when cold) and the escalation of the general friction in the conveyor system (e.g. idlers) at low temperatures.
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TRANSFER OF TECHNOLOGY
Since the day of commissioning, the system has operated with outstanding stability, regardless of the circuitous routing. The belt overlap in all sections is steady and keeps the desired 12- and 6-o’clock-position in the carry and return strand, respectively. Even with the sections partially loaded the behaviour of the belt is stable, showing that under the given challenging circumstances (downhill application, age of the system, condition of idlers, curved routing) the belt for this Pipe Conveyor application is obviously the determining element for the safe operation of the system.
Conclusion
Fig. 14: Power consumption during and after commissioning and after break-in in summer
The installation and commissioning of the new Pipe Conveyor belt was successfully completed between July, 5th and August, 10th 2006, thanks to the excellent and professional cooperation within the project team consisting of ContiTech Conveyor Belt Group, ThyssenKrupp Robins, Inc., Applied Industrial Technologies and Skyline Mine. After the commissioning of the Pipe Conveyor belt and until now, despite some challenging circumstances (downhill conveyor, age of the system, condition of idlers, curved routing), the tracking and overall behaviour remains absolutely stable.
rigidity of the pipe belt in combination with the belt adapting to the conveyor system during the first few months of operation.
For this specific Pipe Conveyor application, the belt construction is determinative for the safe operation of the conveyor system, as a whole. Even with partially loaded belt sections, no change in the belt’s behavior was observed. This indicates that the combination of belt design and the excellent performance of all team members during the planning, splicing, belt installation and commissioning resulted in the successful completion of the belt replacement.
Consequently, both a Pipe Conveyor and a Pipe Conveyor belt should be designed with consideration of higher friction forces during commissioning/break-in period as well as at low temperatures.
The temperature has a very strong influence on the power consumption. In the winter, the power consumption of a Pipe Conveyor is more than 20% higher than in during the summer. This is because of the increased transversal rigidity of the Pipe Conveyor belt (rubber becomes stiff when cold) and by increasing of the general friction in the conveyor system (e.g. idlers) at low temperatures.
At this point authors would like to thank the mine manager Mr. Sorensen and the Skyline Mine employees for their contribution to this project.
The difference in the power consumption between the commissioning time of BC-8 and the period of time after break-in is approximately 30%. The resultant optimal performance is due the reduction of the high transversal
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TRANSFER OF TECHNOLOGY References
Dr.-Ing. Andrey Minkin
[1] Neubecker, I.: An Overland Pipe Conveyor with 22 Horizontal and 45 Vertical Curves Connecting Coal Mine with Rail Load Out. Bulk Solids Handling 18 (1998) Nr. 3, S. 457-462. [2] Keller, M: Zur Optimierung hochfester Stahlseilgurtverbindungen. Dissertation Universität Hannover 2001. [3] Keller, M: Installation of a Conveyor Belt for Hard Coal Shipments with Optimized Energy Consumption in Kalimantan. Surface Mining 55 (2003) Nr. 2. S., 177-184.
ContiTech Conveyor Belt Group Mining Europe Northeim, Germany
Contact: Dipl.-Ing. Andrey Minkin ContiTech Conveyor Belt Group Breslauer Straße 14 D-37154 Northeim
[4] Kahrger, R. Dilefeld, Pohl: Henderson 2000 – A World Class Conveying System, Bulk Solids Handling Vol. 20 (2000) Nr. 3. S. 319-322. [5] Keller, M, Alles: The impact of the German Standard DIN 22101 on Belt Conveyor Design. 2004 SME Meeting & Exhibit Denver, Colorado, USA. [6] Steve and Joseph Vidal: Differentiating between DC and AC motors. [7] DIN 22 101: Stetigförderer. Gurtförderer für Schüttgüter. Grundlagen für die Berechnung und Auslegung. Hrsg. Normenauschuss Bergbau (FABERG) im DIN Deutsches Institut für Normung e.V. und Normenausschuss Maschinenbau (NAM) im DIN. Berlin, Köln: Beuth-Verlag, Ausgabe Februar 1982.
Tel. +49 (0) 5551-702-207 Fax +49 (0) 5551-702-504 ContiTech Conveyor Belt Group As technology leader and the world’s largest manufacturer of conveyor belts, we are the mining industry’s development partner and original equipment supplier. Our conveyor belt systems around the world run reliably and economically, with respect for the environment. As systems supplier, we offer a full range of equipment and comprehensive service, from installation through to start-up.
[8] DIN 22 101: Stetigförderer. Gurtförderer für Schüttgüter. Grundlagen für die Berechnung und Auslegung. Hrsg. Normenausschuss Bergbau (FABERG) im DIN Deutsches Institut für Normung e.V. und Normenausschuss Maschinenbau (NAM) im DIN. Berlin, Köln: Beuth-Verlag, Ausgabe August 2002.
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Issue 02 | 2013
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TECHNOLOGIETRANSFER
High-Performance Performance Mining since 1871 • • • • • • • • • •
Mine development Turn-key mine shafts Delivery of shaft hoisting equipment Shaft and raise boring Exploration and directional drilling Large-hole drilling Freeze-hole drilling Freezing and cementation work Project planning onsulting Engineering and consulting
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Freeze-hole drilling and ground freezing for the sinking and lining of number 1 and number 2 shafts at the ‘Usolski Combine’ Potash Mine in the Russian Federation
Tim van Heyden | Rolf Krause | Eduard Dorn Thyssen Schachtbau GmbH | Mühlheim an der Ruhr | Germany
Fig. 1: Geographic location of Thyssen Schachtbau projects in Russia
Potash mining in the Russian Federation Potash fertilisers are Russia’s most important mineral export by far. This product has until now only been mined in one area, namely at Verkhne-Kamsky in the Perm region, where the world’s second largest reserves of potash salt are to be found. The seam-like deposits in this region are at depth of between 380 and 500 metres, including some 270 metres of water-bearing overburden. Deep mining operations are underway in this region on a vast scale. One of the biggest problems encountered when accessing the underground deposits is protecting the shaft from water inflow and preventing the workings from being flooded. Shafts in water-bearing, unstable ground have traditionally been sunk using the special ‘freeze shaft’ technique. The freeze-wall created around the shaft
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column prevents water ingress into the cavity as the shaft is being sunk. This protective role is then taken over by the permanent lining, once this watertight structure has been put in place.
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TRANSFER OF TECHNOLOGY Freeze shaft sinking has been tried and tested for many years and during this period has proved to be the most reliable special shaft construction technique for conditions of this type. Since the 1930s a total of 24 surface shafts have been sunk in the Verkhne-Kamsky potash region. All these have been freeze shaft sinkings apart from one, which used the cementation method [1]. The choice of sinking method has a huge influence on the future outcome of the entire project.
EuroChem – a growing potash empire Back in 2008 the Moscow-based chemicals company EuroChem announced that it intended to go ahead with the development of the potash mining concession in the Perm region that it had acquired for some 1.4 bn US$. This project would involve the construction of a mining facility with a potash processing plant that would produce potashbased products. The company immediately set about implementing a geological exploration programme that focused on the ‘Palashersky and Balakhontsevsky zones of the Verkhne-Kamsky deposits’. The potash processing plant was initially to be laid out for an annual production capacity of 2.5 million tonnes of potash products, though EuroChem’s long-term plans for the extremely promising Perm project are aiming for six million tonnes of potassium chloride a year. EuroChem is best known as a manufacturer of nitrogen and phosphate based fertilisers and the company is still setting up its potash operations in the Volgograd and Perm regions.
The contract On 29 June 2010 EuroChem commissioned THYSSEN SCHACHTBAU GMBH to undertake planning, drilling and freeze operations for the new skip shaft and service shaft that would be required for the Usolski potash mine in the Perm region of the central Ural Mountains. This gave THYSSEN SCHACHTBAU an opportunity to build on the Gremyachinski project that had already been undertaken in the Volgograd region and in this way expand and develop its business relationship with EuroChem. The new commission is the fourth freeze shaft sinking that the company had carried out for EuroChem. THYSSEN SCHACHTBAU has been involved in freeze shaft sinking for more than one hundred years and these projects have given the company an opportunity to demonstrate its expertise to the Russian market.
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The scope of the contract is as follows: •
Preparation of all project documentation for the approval and execution phase
•
Completion of 90 freeze holes/temperature measurement holes (each about 270 metres in depth) for two shafts
•
Supply and assemble the freeze plant for both shafts
•
Operate the freeze plant, monitor and calculate the freeze wall development for the duration of the sinking operation
EuroChem had set strict deadlines, one of which was that the freeze plant should be commissioned by 1 July 2011. The sinking work was undertaken by a Russian company that in the Soviet Union era had built rocket shafts and underground caverns and bunkers.
Project planning The planning process began immediately after the contract was awarded and was synchronised with the approval procedures and construction sequence. This meant that the construction work could commence without delay and the project could keep to schedule. The planning documents were drawn up strictly in accordance with Russian documentation requirements, as based on the extensive knowledge and experience already acquired in this sector. This not only ensured that the construction work could start on time but also avoided any hold-ups to the approval process.
Drilling work At the time the contract was awarded all the drilling equipment was still in storage in Volgograd. Most of the preparations and repairs were therefore carried out at the depot before the transport operation began. The spare parts needed for the refit were supplied from Germany. The drilling equipment was then transported in its entirety by truck from Volgograd to Beresniki. This meant a 2,000 kilometre trip from the depot to the drilling site. The first items arrived at the site on schedule, on 1 October 2010, along with some of the drilling team. As the standpipes for number 1 shaft had already been delivered by a Russian subcontractor the drilling operation was able to commence on 15 October.
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TRANSFER OF TECHNOLOGY Fig. 2: The drilling equipment was transported in its entirety by truck from Volgograd to Beresniki
Fig. 3: As the first 120 metres of ground contained a number of aquifers that were used as a source of drinking water a pipe connection was run into this zone and permanently cemented up to the surface
The freeze holes for number 1 shaft followed a circle diameter of 17.0 metres and were to be drilled and cased to a depth of 270.6 metres. This involved drilling a total of 41 freeze holes and three temperature measurement holes. As the first 120 metres of ground contained a number of aquifers that were used as a source of drinking water a pipe connection was run into this zone and permanently cemented up to the surface. In order to pinpoint the transition from the overburden to the potash deposits a total of 10.0 metres of drill core were recovered from one of the holes at a depth of between 262.6 and 272.6 metres. These samples were subsequently analysed by the EuroChem geological department.
extremely adverse climatic conditions the drilling operation at number 1 shaft progressed without any weather-related interruptions and was completed on time and to the client’s complete satisfaction. Work on the second shaft began immediately after the first project had been completed. The entire drilling plant was moved and made operational in just three weeks. The second shaft was to have 43 freeze holes and three temperature measurement holes drilled to a cased depth
On 1 November 2010 the good weather suddenly changed and the drilling operation was attended by snow and extreme cold until well into April the following year. Snow 2.0 metres deep, snowstorms and temperatures of as low as -40 °Celsius placed an enormous strain on men and machines. In spite of these Fig. 4: The operation was carried out using the same two RB 50 universal drilling rigs that had been used on the Kotelnikovo project. These highly manoeuvrable, trailer-mounted machines are fitted with hydromechanical drives and come equipped with a mast extension
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TRANSFER OF TECHNOLOGY of 273.6 metres and arranged in an 18 metre-diameter freeze ring. As shaft number 2 was 4.0 metres higher than shaft number 1 the interconnecting pipe at this point was installed and cemented in place to a depth of 125.0 metres. A total of 10.0 metres of core samples were also recovered from one of the drilling holes at a depth of 265.6 to 275.6 metres and sent to EuroChem for analysis. Thanks to the high level of commitment shown by the drilling team, which consisted of German and Russian specialists, the drilling work at number 2 shaft was completed well ahead of schedule. The operation was carried out using the same two RB 50 universal drilling rigs that had been used on the Kotelnikovo project. These highly manoeuvrable, trailermounted machines are fitted with hydromechanical drives and come equipped with a mast extension. The RB 50 has the advantage of being extremely compact and yet features a large hook load of 500 kN and can deliver 31,580 Nm of torque at the power swivel head. The mast extension allows each rig to deploy casings with unit lengths of up to 12 m. A flexibly mounted, 12 m-long deck with integral drill-rod carriage was used as a working/drill-rod platform. The well-proven modular design of the working platform meant that a safe and effective workplace was available for the drilling team to carry out the various tasks required during each stage of the operation.
drilling motors. In addition, to ensure that the measurement equipment operated incident-free at all times a sufficient stock of spare parts was kept at the site and service engineers from the operating companies were also onhand around the clock. The drilling mud circulation was provided by four triplex mud pumps (two per drill), each delivering 1,500 litres a minute, that were permanently installed in 20-foot shipping containers along with their hydromechanical drives and all components required for transport and operation. The pumps were operated from the drilling-rig control console by way of a cable-linked remote control system. A number of centrifugal pumps were connected upstream as booster units in order to maintain trouble-free and efficient operation of the triplex pumps. The continuous monitoring and conditioning of the drilling fluid was carried out in conjunction with a Russian mud servicing company, which also supplied the highgrade reactants needed for preparing the drilling fluid on site. The drilling mud was cleaned and serviced by a combination of de-waterers, a triple-chamber agitator and a series of de-sanders incorporated into the mud system. As mud loss was expected during the drilling operation a total of 120 cubic metres of fluid was kept available in backup tanks together with a sufficient quantity of packing and cementation material. Like the Volgograd project of 2009 the drilling operation also began in the autumn and lasted
Because of the extremely high demands on drilling accuracy when sinking the two shafts for the Palashersky mine the holes were drilled using MWD technology (measurement while drilling) combined with an external, stand-alone EMS (electronic multishot) system. A gyrocompass device was also employed on occasions to measure the inclination and orientation of the drilled holes. This technology, which even operates inside cased holes, allows the course of each hole to be steered in any direction on the basis of the data being received on hole orientation and inclination, with the result that tolerances can be maintained very precisely when drilling the freeze holes. In order to keep stoppages to an absolute minimum a total of six drill motors were kept available throughout the entire drilling phase, with two motor units generally being serviced at any one time. This rotation system effectively eliminated drilling downtime caused by defective Fig. 5: Drilling by using MWD technology (measurement while drilling) combined with an external, standalone EMS (electronic multishot) system
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TRANSFER OF TECHNOLOGY well into the winter season. Winter in the Perm region is somewhat longer, colder, more severe and less predictable than in Kotelnikovo – and the snowfalls are heavier. The project was indeed a challenging one and required the drilling of 90 freeze holes and temperature measurement holes within nine months, including the deployment of the entire drilling plant from one shaft to another.
Technical highlights: • • • • • •
Total drilling distance: 24,976.5 m Total cased pipes: approx. 38,500 m Cement consumption: approx. 1,950 t Diesel consumption: approx. 630,000 l Drill mud consumption: approx. 400 t Outside temperatures winter/summer: -40 °C / +40 °C
The drilling crews were flown-in in turns, a local hotel providing the accommodation. A catering company was employed to supply meals to the workforce on site. Despite the extremely difficult conditions prevailing at the construction site THYSSEN SCHACHTBAU was able to complete the project safely and with almost no lost shift time (illness-related absences constituted less than 1.5 percent of the total working hours, while accident-related absences were less than 0.34 percent). This can be attributed in no small measure to the consistent application of safety regulations by the site management. Each and every operational activity was analysed at the planning stage and the findings were then used to produce operating instructions that were issued
to the workforce as part of their on-site training. Safety training sessions given by experienced drillers completed the programme. The drilling work was successfully completed one month before the contract deadline, very much to the client’s satisfaction.
Freeze work The contract specified that the freezing process should begin at the first shaft and then switch to the second shaft with a time-shift of four months so that the freeze operation could then continue in parallel at the two shaft sites. THYSSEN SCHACHTBAU therefore decided to set up a central freeze plant that would be capable of carrying out the freeze operation simultaneously for both shafts. The two shaft sites were about 150 metres apart and had a height difference of six metres. After examining the plans for the mine site during the sinking phase a decision was taken on the ideal location for the freeze plant and this was then incorporated into the overall layout of the surface facilities. This meant that the plans for the various buildings, with their foundations, power supply and pipe routing from the freeze plant to the shafts, had to take account of the existing and proposed infrastructure. In order to be best equipped for the adverse weather conditions, especially during the winter months, it was decided that the installation’s core components should be erected under the protection of a hangar building. The pipes could then be routed from this
Fig. 6: The drilling team celebrates the end of the drilling phase
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Fig. 7: View of freeze plant and headgear for shaft number 1
hangar through buried concrete ducts to the shaft site. This construction phase also involved incorporating a number of changes that EuroChem wanted to make at very short notice. A large volume of geological and hydrological data had to be analysed in order to determine the required refrigeration capacity. Using the results as a starting point detailed calculations were then produced of the freezewall statics and refrigeration performance. This process eventually established that a maximum refrigeration output of 3,600 kilowatts would be needed for the ground freezing operation at the two shafts. The brine temperature was specified at -40 °Celsius. THYSSEN SCHACHTBAU’s considerable experience in freeze-shaft sinking, which goes back some 100 years, together with the knowledge gained during the Gremyachinski project (report number 17), proved invaluable for planning the freeze plant and designing and refining the associated engineering systems. As in the Palashersky project, the general concept was to provide for a high degree of pre-fabrication of the refrigeration equipment so that the plant could be assembled very quickly at the site. This principle was
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applied to all the components, including the refrigeration machines, pipework and power supply system. The plan was for a total of six refrigeration machines to be installed in containerised modules that were to be completely manufactured in Germany and transported to the site in early 2011. The pipe circuit and all its components were also prefabricated in Germany and pre-insulated as far as possible. The 400-volt power supply was subdistributed into three 20-foot containers that included client-side feed connections and distribution boxes for the refrigeration machines and pumps This essentially led to the development of a modular system that required much less time and effort for assembly and installation on site and meant that THYSSEN SCHACHTBAU could commission the plant before the contractual deadline, which had penalties attached. After eight weeks of assembly and commissioning work EuroChem was able to celebrate the start-up of the freeze plant on 22 August 2011. The operation had involved the installation of 900 metres of pipes, 3,500 metres of power and data cables, five brine pumps with filters and six refrigeration machines.
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Fig. 8: The startup ceremony for the freeze plant was held on 22 August 2011. Photo (bottom): client’s technical managers and members of the Thyssen Schachtbau team in front of the freeze hangar. (Top left): In front of the main brine pipe looking towards number 1 shaft. (Top right): behind the symbolic start button in the brine-pump hangar.
THYSSEN SCHACHTBAU turned to already proven measurement technology for monitoring the freeze process and freeze-wall development. This involved the use of fibre optic sensors for measuring the temperature levels. This system was first employed for the Gremyachinski project and, after a number of modifications and refinements, was then used at Palashersky to take rock temperature measurements for each metre of depth, thereby producing a very detailed temperature profile over the entire freeze shaft column. The accuracy of the system was then further improved with the result that the freeze-wall calculations carried out by
Fig. 9: Ice build-up on the brine pumps
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Fig. 10: Brine heads in the freeze cellar at number 1 shaft.
THYSSEN SCHACHTBAU using this particular set of measurements were able to achieve an even higher level of precision. Incorporating the actual freeze pipe and sensor pipe intervals into the monitoring process produces a very clear image of the actual status of the freeze wall and the ongoing development of the freeze zone can therefore be predicted to an accuracy of within a few percent. All the measurement data were relayed to the central control station so that the freeze plant could be controlled directly at any time for optimum effect. The freeze wall was very soon fully established and the sinking phase was able to commence. On 1 October EuroChem drew the first full bucket of muck from the shaft sinking rig, marking another milestone in the course of the Palashersky project. Having such a finely tuned freeze process available will also mean that the freeze work at number 2 shaft can begin earlier than scheduled. The time interval between the freeze start-ups at the two shafts can therefore be reduced by about 25 percent – which means that the team is aiming to start sinking at shaft number 2 on 1 January 2012.
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TRANSFER OF TECHNOLOGY Summary Thanks to the high level of commitment displayed by everyone involved the operation was completed on schedule and to the complete satisfaction of the client, EuroChem. For THYSSEN SCHACHTBAU the project was a great success, in spite of the huge challenges of having to operate in virgin countryside at the foot of the Ural Mountains. The cordial and cooperative nature of the working relationship with EuroChem was hugely motivating for the workforce, who were keen to do their bit to help develop the new mining complex as quickly as possible.
References
Authors: •
Tim van Heyden
•
Rolf Krause
•
Eduard Dorn
Source: Thyssen Schachtbau Mining Report 2012/2013 THYSSEN SCHACHTBAU GMBH Sandstraße 107 - 135 45473 Mühlheim an der Ruhr www.thyssen-schachtbau.de Tel.: +49(0) - 208 - 3002 - 0 Fax: +49(0) - 208 - 3002 - 327 eMail: info@ts-gruppe.com
VIKOV, Ju. P. ‘Planning and operation of potash mining shafts’, Gorni Journal No. 10, 2[1] OLHO 008
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As Energy Demand Increases Efficiency Gains Are Growing
by Urs Fitze Pictures of the Future - The Magazine for Research and Innovation | Spring 2013 Siemens AG | Munich | Germany
T
he energy equivalent of 0.19 liters — an ordinary glassful — , of oil is needed on average in the world today to produce a commodity with a value of one U.S. dollar. In 1990 a quarter of a liter was required. Today, a further reduction of what is referred to as energy intensity is considered one of the keys to reaching a goal set by the European Union: to reduce CO2 emissions by 80 percent by 2050 as compared to 1990. And in fact considerable progress has been made. In Germany it has been possible to reduce energy intensity from 0.17 to 0.11 liters since 1990. This excellent figure has been exceeded by only a few countries, (e.g. Spain), which in some cases have a more favorable climate. China has also made significant progress. In spite of all the criticism of its immense energy demand, China’s energy intensity has decreased from 0.72 to 0.27 liters since 1990. According to the International Energy Agency (IEA), between 1980 and 2010 energy intensity decreased by one percent per year worldwide — mostly due to technological innovations. For example, the introduction of electronically controlled permanent magnet motors has improved the efficiency of electric motors by up to 95 percent. But despite all the advances, worldwide primary energy use has increased by over 50 percent since 1990. It’s true that during the same period the world’s population grew by a third to 7.1 billion people — but the situation is still sobering. The basic reason for the problem can be reduced to one word: comfort. Today people all over the world require more living space than they used to, and in developing and emerging countries people are driving more and more cars and can now afford things they would never have dreamed of having in the past. But now, according to the World Energy Outlook 2012 of the IEA, all of the key energyhungry countries have laid out ambitious plans to increase their energy efficiency. If these countries take their plans seriously, energy intensity should decrease by 1.8 percent per year between 2010 and 2035, for a total reduction of 36 percent. In order for this to happen, a worldwide annual investment of $158 billion will be necessary. Are such predictions realistic? Certainly. The Fraunhofer Institute for Systems and Innovation Research in Karlsruhe stated as much in a report to the German Federal Environment Ministry. According to the report, by 2050 the European Union’s energy requirements could be 57 percent lower than they were in 1990.
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Around €500 billion in energy costs per year could be saved — in other words, just over 90 percent of the necessary investment could be recovered. Improvements in buildings offer the most potential for increased efficiency. The study shows that the energy needs of buildings could be reduced by 71 percent, mainly through better insulation of existing buildings, modern building technology, and energy-efficient heating and hot water systems. Potentially, energy savings of 53 percent are possible in transportation —thanks to improvements in traffic management, more energy-efficient driving, and improved logistics. Industrial energy demand could also be reduced by 52 percent by 2050. Three fourths of these savings are achievable through improvements in steam generation and electric motors. However, in business and industry the goal is not only energy efficiency, but also cost savings. In the manufacturing sector, materials make up the largest portion of production costs, at over 40 percent. In a survey of almost 1,500 businesses that was carried out for the Federal Ministry of Economics and Technology, the Fraunhofer Institute for Systems and Innovation Research came to the conclusion that around seven percent of material costs could be saved, according to the surveyed companies’ own estimates. That would be a cost reduction of €48 billion per year, mostly in auto and machinery manufacturing, the electronics industry, and the food industry. Reducing energy demand in spite of economic growth — is that possible? It is — under specific conditions. For example, since 1990 Denmark has reduced its energy demand by 18 percent while increasing its gross domestic
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TRANSFER OF TECHNOLOGY product by 41 percent. As early as the 1990s the Danes forged ahead with the construction of natural gas-fired power plants that produce district heating as well as electricity and have an overall efficiency of up to 90 percent. In parallel, the Danes expanded their production of wind energy. Now, businesses are required to use energy more efficiently. Danish power companies are required to become 2.6 percent more efficient every year between 2013 and 2015. And beginning in 2015 they will have to become 2.9 percent more efficient annually. A catalogue of recognized measures defined by the authorities is available to help firms reach these targets in close cooperation with their customers. According to previous experience, this relationship with customers is an important competitive advantage. The EU, which has oriented its Energy Efficiency Directive along the lines of the Danish model, requires power companies to achieve a much more modest 1.1 percent annual improvement in energy efficiency. Therefore the efficiency scenario of the EU’s “Energy Roadmap 2050” utilizes only 72 percent of the savings potential estimated by the Fraunhofer Institute. There is still great potential for energy savings, particularly in industries and private households, say the authors of the study. Nevertheless, the EU is still the international trailblazer. Only a few European countries and a states in the U.S. and Australia have enacted binding regulations for energy efficiency. However, these regulations do not consider socalled “rebound effects.” If the money saved on electricity from the installation of a heat pump, for instance, is spent on air travel or the thermostat is simply turned up, the improvement is meaningless. Rebound losses of ten to 30 percent were revealed in an EU study. In research done by the Wuppertal Institute for Climate, Environment and Energy, economist Tilman Santarius says this figure could be as much as 50 percent in the long term.
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There are no clear ideas on how this can be avoided. Even in Denmark, the lack of better ideas means that progress is ultimately limited to appeals to individuals to become more environmentally conscious and change their behavior. This takes some of the wind out of euphoric predictions about the future. That’s why futurologist Jorgen Randers, in his prognosis for the Club of Rome for 2052, expects only a onethird reduction in energy intensity compared to 2010. That would be more or less a continuation of “business as usual.” Randers believes it isn’t realistic to expect more than this as long as effective incentives — such as a meaningful carbon dioxide tax — aren’t politically feasible. Consumers play a key role in this situation. Through their purchasing decisions, they influence the manufacturing industry. And here there’s cause for cautious optimism. According to a survey recently conducted by the Federal Association for Information Technology, Telecommunications and New Media, 81 percent of consumers said they were prepared to pay more for electronic devices that save energy and resources. Somewhat more than half actually said that they were willing to pay an extra five percent or more.
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Author: •
Urs Fitze
Source: Pictures of the Future | Spring 2013 Siemens AG Corporate Communications (CC) and Corporate Technology (CT) Otto-Hahn-Ring 6, 81739 München Dr. Ulrich Eberl (CC) eMail: ulrich.eberl@siemens.com Tel. +49 89 636 33246 Arthur F. Pease (CT) eMail: arthur.pease@siemens.com Tel. +49 89 636 48824 www.siemens.de/pof
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Fired up about Efficiency
by Sabrina Martin Pictures of the Future - The Magazine for Research and Innovation | Spring 2013 | Siemens AG | Munich | Germany
he challenges that are faced by individual energy systems vary from region to region. But one thing’s for sure: sustainable energy supplies are needed all over the world. Highly efficient T natural gas power plants almost always hold the key to success, as several examples in Asia illustrate.
China is hungry — especially for electricity. The world’s second-largest economy consumes 4,000 terawatt-hours (TWh) of power every year. Annual economic growth of roughly ten percent has enabled China to lift hundreds of millions of people out of poverty in recent years, but this development has led to an immense increase in the country’s hunger for consumer goods, resources, and energy. According to the United Nations, the country will have 1.4 billion people by 2025. The International Energy Agency reports that Chinese oil consumption alone is set to rise by 70 percent from 2009 to 2015. By then China will account for 42 percent of global oil demand. The country’s electricity consumption has tripled in the last decade, and it may double again to 8,000 TWh by 2030. China is therefore looking to make power generation more efficient. Plans call for a radical reduction of CO2 emissions per unit of GDP and the achievement of a much more balanced energy mix by 2030 (see Pictures of the Future, Fall 2012, p. 20), although coal will then still play the major role in the nation’s energy system. The rated capacity for wind farms will increase from 60 gigawatts today to 150 by 2020. However, expanding the use of energy from renewable sources does pose the risk of fluctuation in the grid, since no power can be generated when there is no wind or the sun has set.
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These fluctuations can be offset with combined cycle power plants, which are quick-starting and highly efficient. Shanghai Shenergy Lingang is one such plant. It was honored in October 2012 with the Asian Power Award in the category Best Gas Power Project. Each of Lingang’s four blocks houses an F-series gas turbine from Siemens. Block 4 has set a new efficiency standard for combined cycle power plants in China with its efficiency rating of 59.7 percent and an output of 430 MW — enough to supply electricity to 300,000 people. The power facility is also very flexible. For example, any of its blocks can begin generating electricity just ten minutes after it’s been started up. This feature is now mainly used to react as quickly as possible to the huge demand fluctuations that can rock Shanghai’s power grid on extremely cold winter days or especially hot ones in the summer. Siemens’ solution may also soon be used to balance out the fluctuations that occur when the share of renewable energy in the grid increases sharply. Three Months Ahead of Schedule. Combined cycle plants can also support Vietnam’s efforts to increase its electricity production. Vietnam is one of the fastestgrowing nations in Southeast Asia, and its electricity demand is expected to increase by 11 to 14 percent per year until 2020. According to the Germany Trade and
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TRANSFER OF TECHNOLOGY percent above that of the previous F-Class. The greater size of the HClass also enables further cost savings thanks to economies of scale.
Invest development agency, which is part of the German Ministry of Economics, Vietnam’s demand for energy is increasing roughly twice as fast as its GDP. Power outages are common. Vietnam’s Energy Master Plan for 2011–2020 calls for a threefold increase in output capacity compared to today’s level. One element of the solution is Nhon Trach 2, a 760 MW combined cycle power plant located around 35 kilometers from Ho Chi Minh City. Siemens supplied the plant with a turnkey power block consisting of two SGT54000F gas turbines, two heat-recovery boilers, a steam turbine, three air-cooled generators, and all the electrical, control, auxiliary, and support systems. “Thanks to excellent cooperation between all the project partners, we were able to launch commercial operations at the plant in just 28 and a half months,” says Lothar Balling, Head of Gas Turbine Power Plant Solutions at Siemens Energy’s Fossil Power Generation Division. “We finished our share of the work three months ahead of schedule. That made it one of the most rapidly built power plants in all of Asia. What’s more, the facility’s output and efficiency ratings exceed those that were guaranteed before the plant was constructed, and its emission levels are lower as well. The plant is setting new standards for Vietnam.” This achievement was honored at the Asian Power Awards ceremony, where the facility was named an Outstanding Fast-Track Power Project in 2012.
More Power from Natural Gas. The latest series of Siemens gas turbines — the H-Class — is now operating around 3,000 kilometers away, in South Korea. Siemens has already sold eight of these gas turbines in South Korea since they were launched on the market in 2011. This success is due to the fact that South Korea has very low energy reserves itself and is therefore forced to rely on expensive imported fuels such as liquid natural gas (LNG). That’s just one more reason why the power plants need to be so efficient. For example, an increase in electrical efficiency of just one percentage point in an 800 MW facility results in an additional output of 60 million kilowatthours per year. That’s enough to supply electricity to some 30,000 more people at the same fuel cost and the same CO2 emission level. The fuel issue is particularly important, since fuel costs account for 75 percent of a power plant operator’s total costs. “Efficiency is a crucial concern when one is transforming energy, because natural gas prices are so high here,” says Kwang-Jae Yoo, CEO of Posco Engineering & Construction. Posco is responsible for the construction of the Ansan power plant, which is located in the city of the same name southwest of the South Korean capital, Seoul. “Siemens currently has the most efficient power plant technology, which is tried and tested and has been operating for one and a half years now. Siemens is also an experienced and reliable project partner,” Yoo adds. Siemens is building the plant’s centerpiece — the power island — as a turnkey facility that will include two H-Class gas turbines, a steam turbine, and generators. Ansan will be a combined cycle plant that uses liquefied petroleum gas (LPG) as fuel. When it goes
Siemens has also added its H-Class to the successful F-Class series. The H-Class includes the gas turbine in the Irsching power plant, which achieved the world record electrical efficiency of 60.75 percent in combined cycle operation with a steam turbine at a total electrical output of more than 580 MW in April 2011 (see Pictures of the Future, Fall 2011, p. 96). The H-Class reached an efficiency level that was over 1.5
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TRANSFER OF TECHNOLOGY on line in 2014, it will have a rated gross electrical output capacity of 834 megawatts (MW) and will also provide district heating for the residents of the city of Ansan. This technology ensures optimal exploitation of natural gas and will raise the plant’s fuel efficiency rating to more than 75 percent. The facility’s gas consumption and carbon dioxide emissions will also be one third lower than the average values for existing gas power plants around the world. Siemens built its first combined cycle plant in Asia in Bang Pakong, Thailand, in the early 1980s. The plant had an efficiency rating of around 48 percent. In just three decades Siemens has increased the efficiency of its combined cycle plants by over 12 percentage points. That corresponds to a more than a 25 percent increase in fuel conversion. A further record will be achieved in Germany in 2015. Here, the utility Stadtwerke Düsseldorf recently awarded Siemens a contract for the Lausward power plant, which will feature 595 MW on a single shaft, a net efficiency of over 61 percent, and up to 85 percent fuel conversion. Research in the field continues, as Siemens plans to achieve a combined cycle efficiency rating of over 62 percent by 2020.
A Turbine for the Record Books The H-Class gas turbine is the product of more than ten years of development. Back in October 2000, hundreds of engineers from Siemens’ Energy Sector, Corporate Technology, and about 50 external partner companies began working on the turbine and the concept behind the system. Siemens invested over €500 million in the development, construction, and operation of a prototype facility in Irsching, Germany. The gas turbine underwent a rigorous testing program that included more than 170 starts and over 1,500 operating hours. The facility was then converted into the world’s most efficient combined cycle power plant and handed over in the summer of 2011 to the E.ON power company, which put it into commercial operation. The H-Class turbine has made history with its output of 578 MW and combined efficiency rating of 60.75 percent, as it is the first gas turbine to break the magic 60 percent efficiency mark in combined cycle operation. This exemplary project has even earned an entry in the Guinness book of world records, because the SGT5-8000H turbine in Irsching 4 is the largest operating gas turbine in the world. It has now reached more than 17,800 equivalent operating hours (EOHs), 12,500 of which were in combined cycle operation with more than 400 starts.
Author: •
Sabrina Martin
Source: Pictures of the Future | Spring 2013 Siemens AG Corporate Communications (CC) and Corporate Technology (CT) Otto-Hahn-Ring 6, 81739 Munich
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Dr. Ulrich Eberl (CC) eMail: ulrich.eberl@siemens.com Tel. +49 89 636 33246 Arthur F. Pease (CT) eMail: arthur.pease@siemens.com Tel. +49 89 636 48824 www.siemens.de/pof
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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
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TRANSFER OF TECHNOLOGY BEUMER Group GmbH & Co. KG Beckum | Germany
Customized system solutions for the bulk materials industry:
From component supplier to main contractor
In the difficult terrain, the transportation of bulk materials by truck would require significant detours, extend transport times and substantially increase costs.
T
he ever increasing technical demands in the bulk materials industry are reflected in the particular expectations of the user. Manufacturers who not only supply everything from one source but also undertake the complete project to the point of turnkey handover are in demand. The Beckum-based BEUMER Group with affiliations around the globe develops customized system solutions for conveying and loading, palletizing and packaging, and sortation and distribution systems. BEUMER also acts as the main contractor on behalf of its customers. “A significant trend is that more and more clients want to commission their systems in a turnkey state,” says Dr. Gerd Oberheuser, Head of System Technology at the BEUMER Group, regarding the increased market requirements. “Engineering, Procurement and Construction”, EPC, or EPCM – “Engineering, Procurement and Construction Management” – for short, are the buzzwords here. EPCM is an enhanced form of project management. “This trend can be seen in many parts of the bulk materials industry, for example in cement and opencast mining,” explains Dr. Oberheuser.
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Comprehensive portfolio for the bulk materials industry With the acquisition of Enexco Teknologies India Limited in 2011, the BEUMER Group has expanded its business activities in India and in doing so has strengthened its presence, particularly in the cement industry, in one of the world’s most important growth markets. For example, the portfolio includes horizontal and vertical belt conveyor systems, belt bucket elevators, heavy-duty bucket elevators for particularly large delivery rates and heights, and steel cell conveyors fitted with chains or belts for clinker. The
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TRANSFER OF TECHNOLOGY intralogistics specialist also provides grinding mills, silos and systems for filling, palletizing, packaging and loading. As well as the cement and mining industry, BEUMER system solutions, such as belt conveyors, are also in increasing demand in the coal industry. The conveyor solutions are also used in the firing of power stations. These are also more and more frequently heated with environmentally compatible fuels such as wood pellets, shredded tires and waste. BEUMER supplies suitable systems for transporting the fuels to the boiler, for example.
Changed conditions “For a quotation to be accepted, contracts are often only placed on an EPC basis,” remarks Dr. Oberheuser. This means that, as well as supplying the equipment, BEUMER is responsible for the whole process. This includes the design of the entire system, the installation, the commissioning and the instruction of subcontractors. Not only does a high availability of machines and systems play a decisive role, but also optimum support. For this reason, BEUMER has set up competence centers in the
Czech Republic, in Austria, at its headquarters in Beckum, and in North America. These take care of research and development, sales, project management and purchasing. With its solutions, the BEUMER Group helps users to work more cost effectively and in a more environmentally friendly manner. BEUMER belt conveyors enable companies to transport large quantities of bulk material from the quarry or mine to the factory or port as cost effectively and as quickly as possible. Trucks have considerable disadvantages in this regard. Road building is expensive, and the more raw materials have to be transported from the excavation point to the factory, the more journeys have to be made. Added to this are the operating costs and emissions caused by trucks – both with regard to fuel consumption and personnel costs as well as noise and dust. As a result of the direct route, the material is transported much faster than by truck. In addition, belt conveyors can be operated with significantly fewer personnel. Another aspect compared with trucks is the lower energy consumption, which at the same time reduces CO2 emissions. Depending on the project, belt conveying systems need up to 90 percent less primary energy than comparable truck transportation.
Bulk materials can be transported quickly and efficiently from the excavation point to their destination, even over impassable terrain.
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TRANSFER OF TECHNOLOGY Cost-effective and environmentally friendly conveying Belt conveyors can overcome long distances, steep gradients and tight curves, and can be individually matched to the particular task and topography. Use is made of durable, tension-resistant conveyor belts. In doing so BEUMER uses various calculation programs to determine the optimum belt design. These enable tensile forces to be analyzed and also forces which occur due to acceleration and deceleration – always taking into account the intrinsic weight of the belt and the transported material. They are also used to determine possible curve radii. BEUMER also provides advance feasibility studies. In addition, the belt position is calculated in advance with the appropriate curve radius for the empty and loaded states. With their slender lines, belt conveyors overcome broken terrain and other obstacles such as rivers, roads, buildings or rail tracks. Horizontal and vertical curves in the routing can also be overlapped. Depending on the requirement, BEUMER offers open troughed belt conveyors for higher throughputs and larger mass flows as well as larger curve radii, and enclosed pipe conveyors for products which need to be protected against the effects of the environment. At the port of Callao in Peru, BEUMER will be installing pipe conveyors with a length of around three kilometers for transporting copper, lead and zinc concentrates for completion in 2014. “Depending on the landscape and environmental conditions, we can install overland conveyors with horizontal curves with lengths of up to 20 kilometers,” explains Dr. Oberheuser. Gradients of up to 15 degrees can be realized depending on the characteristics of the
materials to be conveyed. After planning, installation and commissioning, maintenance and service are no more laborious than with a straight conveyor. On average, the annual maintenance costs are only around 2% of the investment sum. In Canada, BEUMER is currently installing a conveyor with a length of 3.48 kilometers for a large mining concern. This will convey up to 6,000 tonnes of iron ore per hour. This large-area conveyor system must withstand extreme temperatures of down to -40 degrees and heavy snowfalls. BEUMER has designed all mechanical and structural elements for the extremely low temperatures. For example, the system is fitted with a feed conveyor and an unloading system with tripper car. As main contractor, BEUMER is equipping a new distribution center off the shore of Malaysia with 17 trough belt conveyors with a total length of twelve kilometers for a large iron ore exporter. The conveyors will ensure swift transport of iron ore from super-size freighters to the mainland. BEUMER will deliver and install the conveyors, put them into operation and take full charge of engineering, all according to a strict timetable.
The BEUMER Group The BEUMER Group is an international leader in the manufacture of intralogistics systems for conveying, loading, palletising, packaging, sortation and distribution technology. Together with Crisplant a/s and Enexco Teknologies India Limited, the BEUMER Group employs about 3,200 people and achieves an annual turnover of about 500 million EUR. With its subsidiaries and sales agencies, the BEUMER Group is present in many industries the world over. For further information visit www.beumergroup.com
FOR MORE INFORMATION AND CONTACT: BEUMER Group GmbH & Co. KG Oelder Str. 40 59269 Beckum | Germany Internet: www.beumergroup.com
Regina Schnathmann Tel. + 49 (0) 2521 24 381 eMail: Regina.Schnathmann@beumergroup.com Verena Breuer Tel. + 49 (0) 2521 24 317 eMail: Verena.Breuer@beumergroup.com Belt conveyors will transport iron ore from the terminal to the port located three kilometers away. (Photo: Vale)
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Kieswerk Kohler GmbH solves fines problem with M2500 from CDE
CDE Global Ltd. Ballyreagh Industrial Estate |Cookstown County Tyrone | BT80 9DG | Ireland
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ollowing installation of the M2500 mobile washing plant Kieswerk Kohler GmbH have addressed the issues caused by excess fines in the material at their quarry in Engen / Welschingen. The solution offered by CDE GmbH has also enabled the production of an additional sand product which the company is now able to offer customers. The raw material being processed by Kieswerk Kohler at the site contains a large proportion of material smaller than 250 microns. With the crushing and screening processes previously employed on the material, the sand was out of specification for use in concrete. “This was causing a problem as local concrete manufacturers are my main customers” explains owner, Thomas Kohler. “I had been working to develop a system which would allow production of concrete aggregates, especially sand. So that it would meet the requirements of the European standards. The solution offered by CDE GmbH has also enabled the production of an additional saleable sand product which I can now offer customers”. CDE GmbH in Heimertingen was formed in December 2012 and represents a development of the previous distributor agreement that was in place for Southern Germany with Jurgen Koelsch GmbH. Stefan Koelsch is the Director of CDE GmbH and he explains the rationale for the formation of the new company. “CDE GmbH gives washing a new focus in Germany. This ensures that we are able to offer aggregate and construction material manufacturers a level of washing expertise, as well as
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project management capability and service support that is only available when construction materials producers buy direct from the manufacturer”. In seeking to address the issues raised by the large proportion of minus 250 micron material in the sand and gravel feed Kieswerk Kohler were investigating the option of washing the material after the initial dry screening process. “We were thinking about several different options and ways in which we could correct the gradation curve of the sand in order that it met the required concrete specification” says Thomas Kohler. “When we explained the issue to CDE they came up with a solution very quickly and since it has been introduced the plant is doing exactly what I wanted it to do”. The processing system introduced by CDE GmbH in Baden-Wurttemberg includes the M2500 E4 mobile washing plant and the AggMax 83 portable logwasher. In addition to the problems caused by the excess fines content in the feed material Kieswerk Kohler were also faced with clays and silts which the dry processing system was not able to effectively remove. The consultation between Thomas
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TRANSFER OF TECHNOLOGY Kohler and Stefan Kolsch revealed that by introducing the AggMax the quality of aggregates produced would also be improved. This solution also helps to maximise sand production from the washing plant explains Stefan Koelsch. “The attrition process within the AggMax plant’s logwasher liberates a lot of valuable fines that would previously have been destined for the aggregate fraction. By aggressively scrubbing the material and returning the liberated fines to the sand washing plant we are ensuring that Kieswerk Kohler recover the maximum amount of sand from the material while also enhancing the quality of the washed aggregate products by removing these fines”. The sand and gravel feed is delivered to the M2500 washing plant by loading shovel and operates at 100 tons per hour The plant accepts 0-100mm material with a grid on the feed hopper rejecting any oversize. The feed material is then delivered to the M2500 aggregate screening phase which is achieved using the integrated Prograde P2-75 rinsing screen. The top deck of this screen separates at +32mm and this material is sent to stockpile via one of the integrated wing conveyors. The bottom deck separates at 4-32mm and this material is then sent to the AggMax for scrubbing via the integrated Rotomax RX80 logwasher. Once material has been processed by the Rotomax it is discharged onto a triple deck horizontal sizing screen which classifies the aggregates into 4-8mm, 8-16mm and 16-32mm.
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The 0-4mm material collects in the Prograde screen sump and is pumped to the integrated Evowash sand washing plant. The Evowash screen is split to allow the production of two sand grades – 0-4mm concrete sand and another 0-2mm product. “The creation of the additional 0-2mm sand product was required as there was too much of this material in the 0-4mm range. The sand washing phase is configured to remove up to 25% of the 0-2mm material from the 0-4mm product to allow for the production of concrete sand” says Stefan Koelsch. An additional benefit for Kieswerk Kohler has been the creation of this 0-2mm sand product which they have now found a market for. “We are able to sell the 0-2mm product as a cable sand” says Thomas Kohler. “This is a bonus for us as our initial focus was very much about getting the concrete sand right. Having a new sand product as a result of the investment is final confirmation that we made the right decision in purchasing the new CDE plant”. As well as selling the final washed products to local concrete manufacturers in Germany some material is also exported into Switzerland due to the proximity of the Kieswerk Kohler site to the Swiss border. The M2500 and AggMax was displayed at Bauma 2013 in Munich between 15th and 21st April.
FOR MORE INFORMATION AND CONTACT: CDE Global Peter Craven Head of Marketing & Sales Support Tel.: +44 28 8676 7900 eMail: pcraven@cdeglobal.com Internet: www.cdeglobal.com
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The new “basics“ of ore crushing
Micro Impact Mill Limited Vaduz | Liechtenstein
How ore material will be crushed in the future. The Micro Impact Mill is far more than an alternative to a ball mill.
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fficiently grinding ore-bearing rock – that is the core business of breakers and mills. For decades now, the particle size of rock has been reduced purelymechanically with these huge machines. This is completely different to the Micro Impact method: here the material in the mill “pulverises“ itself, and thismeans enormous advantages in ore crushing. This innovative Micro Impact Mill amortises quickly because it combines energy efficiency with resourceefficiency and offers the industry at the same time a completely new man¬machine cooperation, completely without silicosis and noise-induced hearing loss. Traditionally, until today the processing of ores takes place in four steps. Several breakers, set in sequence, grind the mined ore to a certain particle size, and then these are further ground in mills, mostly ball mills, with a wet-mechanical procedure. The so generated, pumpable suspension is classified or segmented into different grain categories. The final step for the processing of the orebearing rock is the floating, a physical-chemical step where in water the ore-bearing metal is transported to the water surface through adhering gas bubbles and is skimmed there. The final product is then the ore concentrate. In mining, these large crushing machines are the advance step for ore processing. Depending on the country, region, yield and size of the mine, some dry-working breaker types and a subsequent mill including transport and screening systems form the chain of ore crushing. With the traditional devices, the size of the plant, the energy and logistics effort for the rock material as well as the dust pollution of the environment are tremendous.
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TRANSFER OF TECHNOLOGY How ore material will be crushed in the future. The Micro Impact Mill is far more than an alternative to a ball mill.
Ore crushing in comparison The crushing principle of a jaw breaker for example only works with mechanically generated pressure. The comminution of the crushed material usually takes place in a wedge-shaped shaft between a fixed and a moving, off-centre jaw breaker. During the movement, the rock material is crushed so long until the material is smaller than the pre-set crush gap. The procedure in a ball mill is more refined: In ball mills, the ore-bearing rock that usually has been previously broken up, now grinds together with iron balls within a drum that is put into rotation. The mill material here is “squeezed” by the balls, and this leads to the particle comminution. Including the abrasion of the mill balls, that additionally contaminated the crushed ore with the iron from the iron balls. The Micro Impact Mill uses a completely different comminution method. Here the rock in the milling area is exposed to very high acceleration energy and momentum, and this leads to stone colliding with stone and single grain colliding with single grain according to the chaos principle. Due to self-collision, there is a break in the material itself – without the utilisation of mill mechanics or grinding elements.
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There cannot be any wear and tear, since the exchange of the iron balls in the ball mills can cost the company a fortune.
Quantum leap in ore mining With this innovative mill, in ore processing a new era for crushing machines can start: In comparison with traditional crushing systems, the Micro Impact Mill represents a costoptimised procedure with higher effectiveness that acts in a much more energy¬efficient and at the same time more environmentally-friendly way. Two of the most common reasons for occupational diseases in mining – noise and dust – are a thing of the past with the Micro Impact Mill. In harmony with the tendency towards optimised manmachine cooperation, because the health of the operators benefits from the fact that noise-induced hearing loss and silicosis are no longer topics that deteriorate work conditions.
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TRANSFER OF TECHNOLOGY What is remarkable is the energy reduction that has been achieved, which is no less than 80%. Usually, the performance value for a classical process with breakers and mills is about 750 kW; the Micro Impact Mill needs a mere 35 kW with low initial current values. Noise measurements in operation show a value of 80 dB, whereas with the breakers 130 dB is the rule. The high efficiency of the system can also be seen in the high output of 55 t/h. And this with the small dimensions of the prototype. Variations in the technical design of the Micro Impact Mill offer further process improvements concerning mill material quality and output increase. Wet and/ or dry: both processes function without any problem in the Micro Impact Mill. When adding some water, the mill material quality can be even more refined. If we consider the cost-effectiveness of this mill, this comminution system can replace the traditional sequence of breakers and ball mills. A shorter process of this kind will simplify logistics considerably. After a period of four seconds per filling, there are grain sizes of a diameter up to 300 µm. Almost half of the milled rock can be directly further processed to floating.
MIM Ltd. presents a “ball mill without balls” which is able to completely redefine the whole process of ore crushing. Traditional crushing systems – consisting of several breakers and ball mills – are clearly inferior to the Micro Impact Mill when considering the quantitative and qualitative yield. The ore yield speaks in favour of a pure resource efficiency which opens up completely new potential, for example for mines that have already been closed down. In combination with the aspects of environmental protection, it is the human being that benefits most from the Micro Impact method, because the two primary occupational diseases in mining – noise-induced hearing loss and silicosis – retreat fully into the background. With this technology, mining can be revolutionised without any ball mills and breakers. Visions with this mill point into the right direction towards sustainable mining, which protects man and environment and takes care of the ever increasing scarcity of resources.
FOR MORE INFORMATION AND CONTACT:
Ecology and sustainability The efficient mining of resources is getting more and more attention, especially regarding sustainability and environmental protection. With this Micro Impact Mill,
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Micro Impact Mill Limited Städtle 28 LI -9490 Vaduz | Fürstentum Liechtenstein eMail: info@micro-impact-mill.com Internet: www.micro-impact-mill.com
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Interview:
Micro Impact Mill Limited Vaduz | Liechtenstein
No sooner said than done! T
he mining industry will be delighted with a completely new way of crushingthe ore. The Managing Director of Micro Impact Mill Ltd., Parvis Gharagozlu, explain the background to the development of the Micro Impact Mill, which will improve both raw material productivity and protection. This innovation renders preliminary size reduction by crushing and milling unnecessary and does so ina very energy-efficient and environmentally-friendly way. The Micro Impact Mill is an innovation with the potential to revolutionise the mining industry. Where did the dedication to develop this “ball mill without balls” come from? Take a look at the mining industry: raw materials have been extracted in the same way for over 50 years. Nothing innovative has happened here and I have observed the Chilean copper production for decades now. Always just breaking up, crushing and grinding stones—a really hard business. That´s boring for a mechanical engineer. No innovation, no changes! I´ve been involved in mining in Chile for 30 years. In this time, I haven´t met one person who has been concerned about health and the environment. In terms of my thoughts and my actions, I had reached the point where I wanted to do something about all of the dirt and noise and, at the same time, change mechanical engineering. I can no longer accept that my employees and friends should have to work in this environment. I was quite aware that the principles have stayed the same precisely because resources such as copper and noble earths are becoming increasingly important. Mining technology can´t just keep up with these fashionable terms, such as resource management and sustainable. No, it has to be one step ahead! And that led to the development of the Micro Impact Mill? No, the first ideas and trials with Micro Impact were already there at the start of the nineties. The development of the machine and its technical refinements took several years. Every mechanical engineer knows how much effort needs to be put in before a machine does what it´s supposed to do. I studied mechanical engineering in Germany and, as a result, functional safety and flawless
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TRANSFER OF TECHNOLOGY construction have always been important to me. In the meantime, the Micro Impact Mill has undergone successful test stages and constant optimisations. Long-term tests have been taking place for months in Chile. Now the time is right to present this new and very efficient ore crushing technique to the public.
It´s my aim to bring the Micro Impact Mill to trade fairs with international audiences in Germany.
Where does the efficiency of the mill come from? What is the machine´s technological secret?
Look at it this way: for me this is the first step in showing the industry that sustainable mining is possible. I hope that business models and mechanical concepts will be discussed that relate to how we can use innovative crushing technology in mining. My experiences in copper extraction have also shown that you have to take more responsibility for the environment and not just for technology. Do you know how much energy is being wasted in the mining industry? Can you imagine how much noise and dust pollution today´s ore crushing generates? Who knows how many people are dying of silicosis? For kilometres around you can hear these enormous facilities and dangerous dust is obscuring your view. Exactly at this point, there are chances opening up for the Micro Impact Mill, which could be significant in terms of healthier mining.
It sounds so easy—the stones crush themselves. And that reduces the energy consumption dramatically. You just have to look at the jagged moon: the impact of numerous collisions with asteroids can be seen on the surface there. These large¬scale impacts also affect the earth. With speeds of up to a maximum of 42 km/s total destruction would ensue. Material hits into material and the extremely high amounts of energy pulverise everything. What happens in nature can only be the right thing for mechanical engineering and cheap too. Regardless of whether it´s a meteorite collision or the smallest ore stone, I have harnessed this natural phenomenon in order to carry out crushing mechanically. In the Micro Impact Mill “raw power is exercised sensibly”. The stones´ movement is accelerated, which means that, in accordance with chaos theory, they collide with each other multiple times. In the shortest time, the finest stone powder is produced. Completely different to the other crushers and mills, which need mechanical equipment and iron balls to do this. You have to imagine that the difference between crushing the ore with crushers and mills and using the Micro Impact Mill is comparable to some extent with the move from a prop airliner to a jet plane. Is Germany the right place to be presenting this innovation at the trade fair? What is the motivating factor there? Where else can you find such a well-developed innovation culture for mechanical engineering? Here there are hitech strategies and various initiatives for sustainability and energy-efficiency. Here there are industrial arenas where different sectors meet and discuss change, whether of a technology or business type. It´s vital for me to be aware of the activities and reaction of the market. An innovation has its justification when it works. The initial acceptance from mechanical engineers influences the results for the market or the environment.
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And now you have to wait and see what´s going to happen here? What are your goals for the Micro Impact Mill?
In the meantime, the engineering principle behind the Micro Impact Mill has been patented. The energy potential with this machine is tremendous and that opens up the possibility of a revival of mining in Germany, for example. When you present the Micro Impact Mill to the industry now, what information and facts about it do you include? As prototypes of the machine existed first, I can only give the verified figures for this model. The drive of the Micro Impact Mill has a power value of 35 kW. Comparable data for a ball mill shows that its motor consumes several times more energy. A ball mill in my plant has an instruction from the manufacturer that its power value is 750 kW! With a quantity of ground stone of up to 55 t/h, the Micro Impact Mill demonstrates the lower value of around 40 t/h compared with the ball mill. In operation, the sound measurements with the Micro Impact Mill have a value of 80 dB, whereas 130 dB is the norm for crushers. But it is the energy consumption of both during processing which is decisive. The Micro Impact Mill needs around three quarters less energy than a comparable ball mill! All measurements in each case were carried out on a prototype of the Micro Impact Mill. What needed to be taken into account were the operating costs of the
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TRANSFER OF TECHNOLOGY machine. A ball mill requires the regular replacing of its grinding element and the iron balls cost around US$ 800/ ton according to the size and its procurement. That drives the costs up, but with the Micro Impact Mill these costs wouldn´t arise. Having said that, the Micro Impact Mill has clear procedural advantages for dry and wet processes. Plus there´s the fact that this machine can treat stone and slag. Even bricks from a furnace don´t cause it any problems. In terms of performance scope, the Micro Impact Mill can replace an entire process chain consisting of several crushers and ball mills. The piloting of the machine is very important for me. The principle of micro-impact is the focus. The size and the design of the machine are adaptable. Granule size measurements from Fotec in Vienna have documented a granule size of up to 100 µm in diameter several seconds after it started operating, which can even be refined to 10 µm with an additional drive system. Further expert reviews are still under preparation at the moment. Two more machines are currently being assembled. Both constructions will shortly be going into production and providing evidence that ore crushing with the Micro Impact effect works efficiently. And you´re saying that this machine can replace a whole chain of crushers, conveyor belts and ball mills? Based on the results, the answer is a clear yes. A lot more important are the roles of man and the machine. Everyone has the right to do good work that will challenge and fulfil them, but the conditions aren´t right and the environment endangers their lives, so you have to deal with this situation and change something—even if it is after fifty years! Affordable raw materials for industry remain a fixed building block for the future of industry and the Micro Impact Mill is a modern possibility for bringing man, the environment and technology back into balance with another. The fact that this innovation just works in a cost-effective and efficient way should definitely provoke investment in it Parviz, No sooner said than done !
FOR MORE INFORMATION AND CONTACT: Micro Impact Mill Limited Städtle 28 LI -9490 Vaduz | Fürstentum Liechtenstein eMail: info@micro-impact-mill.com Internet: www.micro-impact-mill.com
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PDAC 2013:
„Stock Day Report“ | Value Relations GmbH Frankfurt am Main | Germany
Vinexpensive gold shares and the comeback of the year!
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he second consecutive year the PDAC in Toronto attracted more than 30,000 visitors from more than 125 countries. There is no doubt: By far this is the most important raw material fair of the world. In the following we will give an overview of trends at the fair. 2013 could be the year of an uranium comeback. Certainly gold plays the biggest role for most of the firms. But which raw material in particular provides great opportunities in 2013? More and more experts answer this question with “uranium”. Here are some facts from the interview on site with the rare metal and uranium expert Chris Berry. Worldwide there are 63 new reactors under construction. 436 are already operating. But currently not all reactors are in operation state. In Japan for example only two out of 52 reactors are in use. Chris Berry expects that up to 30 reactors will be reconnected to the network in the medium term. Thereby the global market for uranium faces a surge in demand. At the present price level of 40 dollars it is not efficient for many producers to give massive support to new projects. According to Chris Berry many of the new projects require prices of 70 dollars and more. This will probably increase the supply shortage.
Even though the German nuclear phase-out has already been decided on, the nuclear energy will not disappear that quickly. This presents various opportunities for promising explorers like Fission Energy for instance. Besides, large producers like Cameco are suspenseful on the actual level.
Gold shares are valued extremely low The presentation of Rob McEwen, founder of Goldcorp and one of the few prominents in the business, is always one of the highlights at the fair. Hence the room was bursting from all seams during his presentation about McEwen Mining. Currently McEwen sees greater opportunities in gold shares than in physical gold. McEwen expects a similarity to the late 1990ies and development of the Goldcorp share price at that time. After a jump in the share price from one dollar to five dollars past the discovery of the high grade Red Lake deposit the share declined back to one dollar by 1999. But after gold price’s low in 2001 the share started to rise at full speed and became one of the great success stories of the resource sector. McEwen believes that a comparable price increase is possible for many gold values, which is a positive sign.
Chris Berry – rare metal and uranium expert
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Shortages in financing
Rob McEwen – founder of Goldcorp
In addition McEwen pointed out the seasonal aspect, that 2012 was an election year in the USA in which especially gold mines have gained above the ordinary measured at the important XAU gold mines index. This has been shown since 1984 and was only interrupted once because of the Bre-X-Scandal in 1996/1997.
Short term pressure is developed because of precarious financial situation of the sector. According to PDAC president Glenn Nolan one of the major bottlenecks is the access to new capital. “The biggest challenge for our sector of the small and medium-sized resource companies is the matter of financing their exploration activities. The problems are exacerbating because of the constantly increasing exploration costs.” Pierre Gratton, president of the Mining Association of Canada (MAC), goes even further. For him the sector in Canada is facing five challenges. In particular he refers to the condition of the resource industry, the regulatory requirements in Canada, the upcoming protectionism due to resources, the lack of qualified professionals and finally the implementation of necessary infrastructure in isolated regions of this huge country. The sector is facing enormous challenges not only in Canada, but also in many other regions of the world.
As a matter of fact the legendary gold investor has ambitious plans for his own company: Until 2015 McEwen Mining should be listed at the S&P 500. To achieve this McEwen has to massively increase the production and especially enhance the market value – but these are things McEwen is familiar with.
The China factor still remains intact In the short term the situation on the resource market is being viewed quite critically. But, according to many experts, in the long term growth is ensured. This thesis was also represented by resource expert Chris Berry from New York for whom the base of former growth are especially the demographic factors. The life expectancy of Chinese children born today is 73 years and herewith they almost reach the rates of the western industrial nations. Just two generations ago their grandparents, born in 1960, only had a life expectancy of 47 years. This means: today Chinese live 26 years longer on average. „26 more years of time for consumption in all aspects of life“, declared Berry at that point. In fact for consumption in different aspects of life different types of resources are needed.
The China factor still remains intact
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TRANSFER OF TECHNOLOGY Conclusion: It is time for cautious optimism It was heard from many companies and also experts: “We reached the bottom or almost doing so.” This is the optimism which could be noticed at the fair and the numerous evening events. Nevertheless, many of the insiders knew that 2013 could become a year of chances in which many weak companies will not persist. After all, a few hundreds of companies only have less than 200,000 dollars kept in the bank. It is unlikely that the money is sufficient until the next PDAC which will take place from 2nd – 5th of March in 2014.
Editor: Value Relations GmbH Gartenstraße 46 D-60596 Frankfurt am Main Tel.: +49 (69) 9592 46-0 Fax: +49 (69) 9592 46-20
„Stock Day Report“
Editorial: Christoph Brüning
Internet: www.stockdayreport.de
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New distributor for Sandvik Construction in the Philippines!
New distributor for Sandvik Construction in the Philippines (Fotos: Sandvik Construction)
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andvik Construction is proud to announce that as of the 16th April 2013, Inframachineries is to be its new distributor for the Mobile Crushing and Screening product range for the Philippines. Inframachineries will not only be supplying a comprehensive range of Sandvik Mobile equipment but will also be providing full aftermarket care, spare parts and dedicated customer service.
New distributor in the Philippines Sandvik a world leader in construction equipment needs no introduction; but now customers throughout the Philippines will be able to benefit from even greater levels of support through its new distributor, Inframachineries. The appointment of such a professional and experienced distributor reinforces Sandviks commitment in providing even greater levels of customer focus, and further enhances its commitment to enhanced locally focused customer support, whilst at the same time allowing customers to benefit from dealing with a truly global company. Inframachineries is a well-established company within the Philippines, with offices, workshops and service engineers operating within the territory. When required, Inframachineries will also be able to obtain additional support from Sandvik Constructions regional office located
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in Muntinlupa City. This will further enable customers to benefit from the specialized advice and assistance that has made Sandvik the world leading supplier of construction equipment. Of the appointment of Inframachineries, Herbert Buder, Global Distributor Manager for Sandvik Construction states: “We are sure that the combination of Sandvik equipment and global aftermarket support, together with the local knowledge and industry expertise of Inframachineries, will enable Sandvik customers throughout the area to benefit from a winning combination.� Inframachineries was appointed Sandvik Construction Distributor on the 16th April 2013, and all at Sandvik Construction offer them congratulations on becoming part of the Global Sandvik family.
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New distributor for Sandvik Construction in the Philippines (Fotos: Sandvik Construction)
Contact: Sandvik Construction Herbert Buder Global Distributor Management Office Phone: +65 6477 6212 Mobile: +65 9727 5158 eMail: herbert.buder@sandvik.com Sandvik Construction Satu Ramo Manager Marketing Communications Mobile: +358 40 537 4020 Office Phone: +358 205 44 161 Fax: +358 205 44 160 eMail: Satu.Ramo@sandvik.com Internet: www.construction.sandvik.com
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Sandvik Group Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK.
Sandvik Construction Sandvik Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunneling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees (pro forma rounded numbers).
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New President appointed to Sandvik Construction! D
inggui Gao has been appointed President of Business Area Sandvik Construction and member of the company’s Group Executive Management. He has experience from leading positions in global industrial companies.
Sandvik Construction is specialized in equipment, tools and service for niche applications in the construction industries. In 2012 Sandvik Construction was designated a core business area within Sandvik. Sales reached 9,7 BSEK and it introduced more than 30 new products for the business area’s different customer segments and markets. Dinggui Gao is 49 years of age. He was previously at MAN Group as its executive representative at one of its invested companies, Sinotruk Hong Kong Ltd. Prior to this, he was employed by Honeywell, Eagle Ottawa and also for more than a decade held progressive leading positions in the Bosch group. “I look forward to Dinggui Gao joining us at Sandvik. His experience and background are valuable for us, particularly his background within international business environments which are of great significance for Sandvik, being a corporation with a strong global position,” says Sandvik’s President and CEO, Olof Faxander. Dinggui Gao takes on his new position at a date that will be announced later.
Contact: Sandvik AB Pär Altan Vice President Group External Communications Office Phone: +46 8 456 12 37 Sandvik Construction Satu Ramo Manager Marketing Communications Mobile: +358 40 537 4020 eMail: Satu.Ramo@sandvik.com Internet: www.construction.sandvik.com
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New President appointed to Sandvik Construction Dinggui Gao (Fotos: Sandvik Construction)
Sandvik Group Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK.
Sandvik Construction Sandvik Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunneling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees (pro forma rounded numbers).
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TRANSFER OF TECHNOLOGY
President of Bayern Munich guest of honor at Sandvik Global Construction Press event! O
ne of the key industry occasions that is always looked forward to at Bauma is the Sandvik Construction press event. This Bauma was no exception, and this year approximately 50 publishers, editors and journalists from the worlds construction press joined Sandvik at the press event on the Wednesday evening. During the event, amongst other activities, those in attendance were treated to a key note speech from the guest of honor, Bayern Munich President, Mr. Uli Hoeness. The worlds construction press joined Sandvik on the Wednesday evening of Bauma, with over 50 journalists, editors, free-lancers and publishers, representing some of the most prestigious construction titles from all corners of the globe, coming to the stand. Upon arrival Sandviks esteemed guests were treated to a reception, before being entertained by the famous “Trommelfeuer� drummers. Following on from the initial entertainments the guests then took part in a formal press conference. The press conference began with a short introductory speech from Andy Taylor, acting President of Sandvik Construction, who after welcoming our guests handed over to Kauko Juuri, President of Global Market, who introduced the evenings events. He then commented on the global construction business outlook, discussed Sandviks product focus and launches, before introducing the Sandvik Product Line Specialists, who later discussed in detail their specific offering.
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A key note speech from the guest of honor, Bayern Munich President, Mr. Uli Hoeness (Fotos: Sandvik Construction)
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TRANSFER OF TECHNOLOGY
Mr. Hoeness discussed many topics that were pertinent to the construction industry and football, drawing on the many similarities of these two diverse business worlds (Fotos: Sandvik Construction)
With the formal press event finished guests were then invited to join the Sandvik team for dinner and enjoy the special entertainment. There was however one more treat for the world press as a special surprise was laid on in the shape of a guest speaker, Mr. Uli Hoeness, President of Bayern Munich football club. During his speech Mr. Hoeness discussed many topics that were pertinent to the construction industry and football, drawing on the many similarities of these two diverse business worlds. The choice of Mr. Hoeness to give a speech was particularly apt due to the many similarities that exist between Sandvik and Bayern Munich FC: both organizations have been successful for over 100yrs, are acknowledged leaders in their field, place great stress on the development and personal growth of their employees, whilst actively playing a part in the community in which they operate. The latter was highlighted as following his speech Mr. Hoeness was presented with a cheque made out to a local childrens charity, Shekki, as a token of Sandviks appreciation for donating time from his busy schedule.
The Sandvik Bauma press event proved to be a great success, with the occasion being enjoyed by all, as well as being found to be highly informative. Sandvik would like to thank our colleagues from the Global Construction Press, and a special thanks to Mr. Uli Hoeness for delivering such an inspirational speech.
Contact: Sandvik Construction Satu Ramo Global Manager Marketing Communications Mobile: +358 40 537 4020 eMail: Satu.Ramo@sandvik.com Internet: www.construction.sandvik.com
Sandvik Group Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK.
Sandvik Construction Sandvik Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunneling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees (pro forma rounded numbers).
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TRANSFER OF TECHNOLOGY ThyssenKrupp Steel Europe | ThyssenKrupp Electrical Steel
ThyssenKrupp: Mastering challenges!
O
ur unique materials expertise gives our customers a competitive edge. ThyssenKrupp is one of the world’s leading suppliers of flat carbon steel. Many of our materials were specifically developed for extreme conditions –ideal for the minerals & mining industry. Our innovativeness is also reflected in PowerCore® electrical steel, a high-tech material that sets new standards of efficiency.
Longer Life Our XAR® steels open up new possibilities for the minerals & mining industry, where wear and abrasion place very high requirements on materials. These steels significantly extend the service life of components. Their extremely high hardness is achieved through a combination of chemical composition and a specialized heat treatment process.
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TRANSFER OF TECHNOLOGY XAR® special structural steel for heavy truck dump bodies
Heavy plate as robust basis Heavy plate from ThyssenKrupp is ideal for highly stressed steel structures. It guarantees maximum robustness and strength with significantly lower weight. In the minerals & mining industry it is used wherever heavyduty materials are required, for example, in dump trucks, crawler-mounted vehicles and excavators. Our wear-resistant XAR® steels are the perfect solution for manufacturers of excavator buckets, crushers, conveyors and screens. Their high hardness allows our customers to significantly extend the service life of wear parts. We developed the ultrahigh-strength N-AXTRA® and XABO® steels to reduce the weight of highly stressed structures such as mobile cranes and shields in underground mining.
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Heavy plate in detail •
Use of heavy plate as starting material, for example, for floor panels
•
XAR® special structural steels offer extremely high wear resistance, for example, for truck dump bodies, excavator buckets, crushers, and side plates for charging hoppers, and are available in various grades and sizes: Thicknesses from 3 to 100 mm, widths up to 3,600 mm
•
N-A-XTRA® and XABO® special structural steels for the manufacture of bucket wheel excavators, cranes, overburden machines and shield components to the highest standards of safety, available in various grades and sizes: Thicknesses from 3 to 100 mm, widths up to 3,300 mm
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TRANSFER OF TECHNOLOGY PowerCore® electrical steel for maximum energy efficiency
The texture of the material determines the special magnetic properties of electrical steel
ThyssenKrupp is a premium manufacturer of electrical steel and one of the world market leaders in this area. Under the PowerCore® brand we supply this highly specialized steel grade as grain-oriented and non-oriented electrical steel. High-tech PowerCore® electrical steels offer excellent processing and magnetic properties and maximum energy efficiency. Our products are available worldwide for the production of highly efficient electrical machines. The unique texture and resultant soft magnetic properties of grain-oriented electrical steel allow trans formers to operate at over 99% efficiency. The material thus makes an important contribution to conserving resources and protecting the environment.
PowerCore® electrical steel in detail •
Use of non-oriented electrical steel in the minerals & mining industry, for example, as a starting material for generators, motors and other elec trical components. Available in the variants fully finished (PowerCore® A), high-permeability (PowerCore® AP) and semi-finished (PowerCore® K) in a variety of grades and thicknesses from 0.2 to 1.0 mm
•
Use of laminated or wound grain-oriented elec trical steel as core material for power and distribution transformers as well as small transformers. Available in the variants PowerCore® C (conventional grades) and PowerCore® H (high-permeability grades) in thicknesses from 0.18 to 0.35 mm.
FOR MORE INFORMATION AND CONTACT: ThyssenKrupp Steel Europe AG Heavy Plate Mannesmannstr., Tor 9 47259 Duisburg | Germany Tel.: +49 203 52-75604 Fax: +49 203 52-75653 Internet: www.thyssenkrupp-steel-europe.com ThyssenKrupp Electrical Steel GmbH Kurt-Schumacher-Str. 95 45881 Gelsenkirchen | Germany Tel.: +49 209 407-0 Fax: +49 209 407-50832 Internet: www.thyssenkrupp-electrical-steel.com
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TRANSFER OF TECHNOLOGY ThyssenKrupp FĂśrdertechnik
ThyssenKrupp: Greater efficiency! W
hen it comes to the mining, crushing, transporting and spreading of ores, minerals, coal and overburden, ThyssenKrupp has unique expertise. With our innovative equipment and detailed planning services, we can design the entire continuous surface mining process to maximize efficiency. For this we constantly explore new paths.
Continuous surface mining In rock quarries, crushers reduce the rock or overburden directly at the face and the material is then transported away on belt conveyors. ThyssenKrupp has advanced the development of these in-pit crushing systems and is one of the world’s leading suppliers.
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Our mobile and semi-mobile crushers achieve throughputs of up to 14,000 tons per hour. Fully mobile crushers are an outstanding example of innovative engineering; their use lowers transportation costs in mining operations by up to 50% and dispenses completely with the need for heavy trucks. Our crushers are powered exclusively by electricity, which means that mine operating costs and CO2 emissions can be significantly reduced.
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TRANSFER OF TECHNOLOGY Surface mining equipment and systems in detail •
Bucket wheel excavators, complete bucket wheel excavator systems
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Beltwagons, tripper cars
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Spreaders
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Stationary, relocatable and shiftable belt conveyor systems, long-distance and curved belt conveyor systems
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Transport crawlers
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Stationary, semi-mobile and fully mobile crushers, complete in-pit crushing systems
A break with the past Our fully mobile crusher is revolution izing the surface mining industry. It reduces the raw materials directly at the mine face so that they can then be transported away on belt conveyors – the use of heavy trucks is no longer required. This significantly reduces operating costs and cuts CO2 emissions by up to 350,000 tons per year.
FOR MORE INFORMATION AND CONTACT: ThyssenKrupp Fördertechnik GmbH ThyssenKrupp Allee 1 45143 Essen | Germany Tel.: +49 201 828-04 Fax: +49 201 828-2566 Internet: www.thyssenkrupp-foerdertechnik.de
Beltwagon and two fully mobile crushers on an assembly area
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TRANSFER OF TECHNOLOGY
Optimized for Extreme Challenges Individually-packaged standard
SEW-Eurodrive Bruchsal | Germany Olaf Meier,
components are used to drive scraper chain conveyors in Spitsbergen
The scraper chain conveyor in Spitsbergen can transport approximately 450 tons of coal per hour.
high torque of up to 130 kNm, a reduction ratio of 118 to 1 and temperatures that drop below minus 30 degrees Celsius – operating a scraper chain conveyor for a coal mine in A Spitsbergen presents extreme challenges for the drive technology. Thanks to SEW-Eurodrive’s comprehensive range of standard motors and standard industrial gear units, Halbach & Braun were able to create the perfect cost-efficient drive for these extreme conditions. With their coal mines in Spitsbergen, the largest island of the Svalbard archipelago in Norway, Store Norske is the northernmost mining company in the world. The climate is arctic with a yearly average temperature of minus 4.4 degrees Celsius; the polar night lasts from the end of October to mid-February. Despite these adverse conditions, the mining business is profitable in this region because the coal deposits often reach the ground surface. In spring 2012, the company began excavation of an additional mine in the Lunckefjell region. The Lunckefjell mountain contains an estimated 8.2 million tons of high-quality coal. There is high demand for this coal on the European market for metallurgic processes, among other uses.
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Scraper chain conveyors – The backbone of the mining industry Once the infrastructure has been installed over the course of the year, Store Norske now begins setting up the machinery. For their requirements, the Norwegian company is relying on the experience in the field of mining, which the German mechanical engineers have acquired over decades in the Ruhr valley. That’s why Halbach & Braun will be sending a scraper chain conveyor to Spitsbergen. “This conveyor is the most important element for transporting the excavated material, that is the quarried stones, from the area of extraction to the place where it will be crushed and processed,” explains Dr. Dietrich Braun, Managing Partner of Halbach & Braun. Scraper chain conveyors are
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TRANSFER OF TECHNOLOGY The conveyor is equipped with a double drive. Each drive consists of an AC motor of the DRE series with 37 kW and a fourstage industrial gear unit of the X series in size 190.
this plate. The drivers transport the material slowly and continuously out of the bunker. The conveyor for Store Norske transports around 450 tons per hour. “A lot of power is required to get the coal out of this heavy mass,” explains Dr. Braun. “Accordingly, a drive with an extremely large reduction ratio is required in order to generate the required torque.” The experts from Halbach & Braun calculated the operating torque for the Store Norske conveyor to be 29.4 kNm; the nominal torque is 130 kNm. “Despite the high torque, we only require a low power rating for the motor because the speed of the conveyor is relatively slow,” says Dr. Braun.
High torque, low power
the key product for the medium-sized company, which was founded in 1920 by Dr. Braun’s grandfather. The company, which is located in Hattingen, Germany, employs around of 55 employees who construct crushers, coal ploughs and belt ends, which are the connecting elements between the scraper chain conveyor and the conveyor belt.
Working with 120 ton loads Store Norske ordered a scraper chain conveyor intended to be used for surface mining. The conveyor will not be located directly at the mining location; instead the excavated material (chunks of stone) will be supplied by large trucks. They will deposit their loads into an 80 m³ bunker, from which the scraper chain conveyor will continuously extract the coal. “When the bunker is filled, up to 2 tons of heavy stones fall onto the conveyor from a height of many meters; if the bunker is filled to the edge, it is under 120 tons of material,” says Dr. Braun, describing the extreme loads. “Only a scraper chain conveyor can withstand these kinds of loads.” That’s because the material is not placed on a belt, but rather on a fixed steel plate that can be up to 5 cm thick. Horizontal drivers that are connected and driven by two chains “scrape” over
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This combination of high torque and low motor power requires an individual drive solution. “For these kinds of challenges, we generally rely on drives from SEWEurodrive,” continues Dr. Dietrich Braun. “That’s because SEW has a large portfolio of standard components from which you can quickly create the perfect, individual drive solution. Because the components are manufactured in large quantities, the drives are also available at an attractive price – despite individual configuration.” Tailored drive solutions are essential for Halbach & Braun, because the medium-sized company uses machines that are individual solutions, optimized for the specific requirements of the mining company. “I can adjust and rework the configuration with my customers as much as I want and still be sure that SEW-Eurodrive will be able to supply me with the right drive,” says Dr. Braun. When designing the scraper chain conveyor for Store Norske, SEW-Eurodrive’s Technical Office in Dortmund suggested that Halbach & Braun use a double gear unit for chain conveyors for the drive configuration project. An AC motor from the DRE series with 37 kilowatts of power was combined with a size 190 four-stage industrial gear unit from the X series.
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Individual solution from the standard modular system The DR series of motors are the “global motors” in SEWEurodrive’s product portfolio. They conform to a wide range of international manufacturing specifications such as IEC EN 60034 or NEMA MG1. Thanks to its large voltage range, it is possible to achieve various voltages anywhere in the world with one motor. The “E” version stands for the “high efficiency” energy efficiency class in accordance with IE2. The motors are flange-mounted onto the series X gear units using extended housing and elastic couplings. These industrial gear units are available in a number of different versions. They are perfect for the kind of individual drive solutions that Halbach & Braun require. The robust helical and bevel-helical gear units cover a torque range from 6.8 to 475 kNm and a gear ratio range from 6.3 to 450. The gear unit concept offers finely graduated sizes, variable installation and a wide variety of modular options. A large quantity of pre-defined optional equipment increases the flexibility of the solution. This includes a wide range of modular options such as motor adapters and mounting flanges, backstops and cooling systems as well as sealing systems for the most varied ambient conditions. “For
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The motor, which has an output of 160 kW, drives the rotor of the crusher using a V-belt. This reduces the impact on the motor and prevents damage in the case that the crusher gets blocked.
example, the motors for the scraper chain conveyors are equipped with an electrical heating system, which can be ordered from our catalog as a standard variant,” according to SEW expert Thomas Vogt from the Dortmund Technical Office who managed the project planning for the drive. The heating system ensures that the gear unit oil maintains the required viscosity even when subjected to the extremely low temperatures in Spitsbergen. A third SEW motor, also from the DR series, but with a performance of 160 kW, supplies the drive for the crusher which is mounted halfway up the conveyor line. “Scraper chain conveyors consume a lot of energy, which is why we tried to keep the conveyor line as short as possible,” explains Dr. Braun. “The crusher breaks up the excavated material into smaller pieces with a maximum size of 300 mm. This allows it to be transported further on rubber belt conveyors, which are more energy efficient.” Rather than using a gear unit, the motor drives the rotor of the crusher using a V-belt. This reduces the impact on the motor and prevents damage to the drive in the case that the crusher gets blocked.
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TRANSFER OF TECHNOLOGY Fine-tuning using inverters All motors are operated using SEW inverters of the type Movidrive. “The customer can finely adjust the drive using the frequency inverter,” explains Dr. Dietrich Braun. “This is important because the amount of material that is transported out of the bunker really depends on the kind of material that was excavated: Wet coal is extremely sticky, which means that more material is transported out of the bunker. To prevent the crusher from becoming overloaded, the speed of the chain drives can be reduced using the inverter.”
Service beyond the Arctic Circle If at some point a drive gets damaged, Halbach & Braun can rely on SEW-Eurodrive’s global service network: “We have subsidiaries in Norway and Finland that can provide help fast in Spitsbergen,” emphasizes Roger GoekeZimmler, who works in Sales at SEW for industrial gear unit systems. However, Dr. Dietrich Braun is confident that he won’t need this service: “Before we began the project, we had long discussions with SEW-Eurodrive about the conditions on-location – the temperature range, moisture protection, oil viscosity, etc. – so we won’t have any unpleasant surprises. To this day we have never had a problem with SEW drives.”
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FOR MORE INFORMATION AND CONTACT: SEW-EURODRIVE GmbH & Co KG Market-management Ernst-Blickle-Straße 42 76646 Bruchsal Internet: www.sew-eurodrive.de/ Mr Gunthart Mau Trade press Tel.: +49 (0)7251 75-2588 Fax: +49 (0)7251 75-502588 eMail: gunthart.mau@sew-eurodrive.de SEW-EURODRIVE GmbH & Co KG Press and Public Relations Ernst-Blickle-Straße 42 76646 Bruchsal Internet: www.sew-eurodrive.de/ Tel.: +49 (0)7251 75-0 eMail: sew@sew-eurodrive.de
Dr. Dietrich Braun, Managing Partner of Halbach & Braun (r.), and Roger Goeke-Zimmler, SEW sales engineer at the Dortmund Technical Office at the acceptance of the scraper chain conveyor.
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TRANSFER OF TECHNOLOGY Allmineral Aufbereitungstechnik GmbH & Co. KG
Kumba´s Sishen Expansion Project:
FINE TUNING AT THE CAPE
allmineral: sishen
allmineral, the Duisburg-based mineral processing specialist, has fulfilled the single largest machine contract in its history with the design, engineering and delivery of 24 alljig® jigs to Kumba’s Sishen Expansion Project (SEP) in the Northern Cape Province of South Africa. The order was received from Kumba Iron Ore Ltd., South Africa’s largest iron ore producer and number four worldwide. SEP is set to boost the growth of the domestic iron ore industry. New deposits adjoining the existing opencast mine, supplemented by an option for another mining area, have been under development since 2005. Estimated investments in the country’s entire mining sector are running into double-figure billions. Efforts by the South African government to upgrade its infrastructure will considerably improve its position for successful growth. Kumba initially opted for 18 alljigs® from allmineral in autumn 2005. However, following extensive tests in mid-2006, an additional six alljig® machines were ordered for the project. The alljigs® are installed in eight modules, each with three different sized alljigs® for the various iron ore sizes. The machines were
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delivered in a phased approach with the first units on site in September 2006 and the second consignment in spring 2007. Commissioning began in autumn 2007, with completion in summer 2008, and Kumba employees have received extensive training to ensure optimum operation of the machines.
Advantages for Iron Ore Extraction The coarse feed material, with a particle size from 8mm to 25mm, is processed in the first stage of the eight modules in the alljig® G(UB) – these machines are 4000mm x 3000mm. The second stage, with 3500mm x 3000mm alljig® M(UB) machines,
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TRANSFER OF TECHNOLOGY processes medium size particles, from 3mm to 8mm. The alljig® F(UB) machines, 2200mm x 3000mm, process marketable products including fines with a particle size from 0.8mm to minus 3mm. With a throughput rate of over 4000 tonnes/hr, the integrated plant with its 24 units is the largest of its type in the world. All machines work with a three-chamber system. For the purpose of separation, water flows through the material bed; the water current, pulsating upwards, loosens the material, and is virtually a wear-free operation. Besides this highly efficient technology, the allmineral machines offer flexibility, allowing the jigs to be adjusted during production to cater for changing parameters, such as a change in the feed material. The use of allmineral alljigs® within the beneficiation plant has enabled Kumba to tap into two new sources for marketable iron ore products. Firstly, the company will now be able to process material which was previously considered overburden – allmineral alljigs® offer a high degree of efficiency with a guaranteed export quality of 64% Fe in the final product. The same, but a much more sustainable effect, is derived from the development of additional deposits at Sishen. The quality of the iron ore is not as high as in material from other Sishen deposits, which makes processing more difficult and more complex. However, the efficiency of the alljigs®, coupled with the persistently high world market prices, make the extraction of this material profitable, and the lifetime of the mine has been lengthened by almost 20 years. This corresponds to more than 300 million tonnes that can be produced thanks to new mineral processing methods.
Growth in Response to the Raw Materials Demand Since the award of the contract by Kumba to allmineral in October 2005, more than 100 alljigs®, 50 allflux®, and 80 gaustec® WHIMS have been sold to the iron ore industry worldwide – not only to South Africa, but also to India, Australia, Canada and Brazil – a real success story, which is making allmineral the #1 when it comes to upgrading low grade iron ores, wherever in the world.
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
About allmineral
allmineral is a world-renowned specialist in the preparation of gravel, sand, coal, slag and ore. Our system solutions are oriented to the individual needs of our customers, market conditions and the quality of the raw materials available. In close cooperation with our customers, our qualified staff develops an optimal concept, builds the appropriate system and ensures trouble-free operation..
allmineral: sishen
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TRANSFER OF TECHNOLOGY Baresel GmbH & Co. KG | Hazemag & Epr GmbH
HAZEMAG
IMPACTS ON PRODUCTION PROFITS
Baresel GmbH & Co. KG, one of the most successful gravel and limestone producers in South West Germany, has significantly increased production capacity by investing in horizontal-flow crushing and screening technology from HAZEMAG. HAZEMAG & EPR GmbH was awarded the contract for a new primary crushing plant in June 2011 and, at the customer‘s request, delivery of the plant took place at the end of April 2012. Following commissioning, the plant has been in continuous use since July 2012 – completely satisfying the customer‘s expectations, and contributing to a marked increase in production profits for the company. The new primary crushing plant has a throughput capacity of 900 t/h, and is employed on the pre-crushing of limestone at the company‘s Ehningen site, near Stuttgart. Production from the site includes aggregates for use in the ready-mixed concrete and precast concrete sectors, as well as high-quality chippings for asphalt mixing plants.
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The wide range of products extracted at the Ehningen site comprise shell limestone; suitable for all types of application in road building, landscaping and concrete construction. Specific requirements for the crushing plant were clearly defined at the planning stage and called for a versatile plant with a high degree of mobility; the plant had to be capable of following quarrying extraction, directly at the working area, and of fulfilling the requirements of both current and future quarrying advances.
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Taking into consideration the above targets and design criteria, the customer decided in favour of HAZEMAG‘s horizontal-flow impact roll crusher SS 1518 R. Feed to the crusher is via an integrated scraper chain which conveys the material directly to the impact chamber of the crushing roll. A pre-screening roller screen, type RR 0.6 x 15 x 25, is integrated with the chain conveyor and screens out <60mm fraction – considerably reducing the amount of fines generated in the crushing process .
Auslegungsdaten /Design data: Aufgabematerial / Feed material Aufgabekorn / Feed grain size Zielkörnung / Target grain size Durchsatzleistung / Throughput rate Beschickung / Feeding
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The crushing plant employs two integral belt conveyors for material discharge: conveyor no.1, positioned beneath the roller screen, discharges the pre-screened material laterally, whilst conveyor no.2, located beneath the chain scraper discharge, directs the crushed product onto a further belt conveyor. In order to be able to move the crusher easily around the quarry area, it was fitted with a powerless crawler track - a switch box serves as the control centre which, depending on the planned cable length, may be placed near the plant
Kalkstein / limestone 1400 x 800 x X mm / 1400 x 800 x X mm 0 - 300 mm + Überkorn / 0 - 300 mm + oversized grain 900 t/h inkl. Vorabsiebung / 900 t/h including primary screening Radlader, 50 t / wheel-type loader, 50 t
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TRANSFER OF TECHNOLOGY HAZEMAG GROUP today Headquartered in Dülmen, Germany, and part of the Schmidt Kranz Group, Hazemag & EPR GmbH has a long track record as a provider of outstanding engineering and class-leading products, with a history dating back to 1842. During 2012, the company was transformed from being a specialised crusher supplier, mainly for the cement and aggregates industries, into the Hazemag Group – a solutions provider for minerals processing, supported by its newly-created business development centre. The Hazemag Group can now offer a complete range of crushing technologies: Building on years of experience in crushing with impactors and hammer mills, Hazemag now offer hard-rock gyratory, cone, and jaw-crusher technology, through its South African subsidiary IMS Engineering, and the acquisition of MinPro brought impact roll crushers and feeder-breakers to its portfolio. The company has also increased its ability to supply customers with turnkey projects in mineral processing. Its acquisition of Allmineral has brought expertise in coal and ore beneficiation technologies to the group, whilst the integration into Hazemag of the long-established engineering firm Saarmag, has given it the ability to offer systems for transporting, stacking, reclaiming and stockpiling bulk materials.
Hazemag has also been active in supplying new crushing concepts to the diamond industry. After extensive testing, it designed crushing technology for a famous diamond manufacturer that significantly reduces stress on the diamonds during ore crushing and, as a result, minimises losses during subsequent processing. Underground and open-pit coal processing is also an important market area for the group: The capabilities of Hazemag’s crushing and mine-development equipment are renowned in longwall applications; and allmineral’s wet and dry jigs are widely used in coal beneficiation. Hazemag has also built on its success in supplying openpit mobile and semi-mobile crushers, with units recently commissioned in China and south east Europe. Finally, Hazemag’s impact crusher technology continues to provide a reliable crushing solution for the cement and aggregates industries, with the company providing customised solutions, including complete processing plants, to address customers’ specific requirements.
As an example of its capabilities, Hazemag recently installed a complete primary-to-tertiary crushing plant at one of South Africa’s largest iron-ore mines. In the plant, a primary gyratory followed by two secondary gyratory crushers and four tertiary cone crushers, reduce the ore down to minus 30mm. Hazemag followed this by supplying a complete processing plant based on allmineral’s jigging technology, employing 24 alljigs®, and creating the world’s biggest iron-ore beneficiation plant.
FOR MORE INFORMATION AND CONTACT: HAZEMAG & EPR GmbH Brokweg 75 48249 Dülmen | Germany Tel.: +49 (0) 25 94 77 - 0 Fax: +49 (0) 25 94 77 - 400 eMail: info@hazemag.de Internet: www.hazemag-group.com
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TRANSFER OF TECHNOLOGY Hammerfall Dolomitt A/S | Hazemag & Epr GmbH
Hazemag Group:
CRUSHING PLANT FOR DOLOMITT A/S
In March 2012 HAZEMAG Group secured an order from Hammerfall Dolomitt A/S, in Røsvik, Norway, for a complete crushing plant designed to process dolomite stone at a rate of 600 t/h With the operating site for the new plant being approximately 80km north of the Arctic Circle, Hazemag engineers were required to design the plant for operation at extreme temperatures of minus 40°C. A further key requirement for the plant was that it should be capable of accepting extremely large-sized feed material and be able to produce a consistently high quality cube-shaped product, with fines content kept to an absolute minimum. To fulfil the requirement, HAZEMAG designed a processing plant which includes a HAZEMAG KF1500 chain conveyor as a feeding unit for the primary HAZEMAG HCS 1020 centre-sizer. Crushed material is then screened, via a 3-stage roller screen, prior to secondary crushing by a HAZEMAG HCS 0820 centre-sizer. In addition, a stockpile belt conveyor, complete with belt-weigher and a de-dusting plant, was part of the scope of supply.
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The dolomite stone, extracted underground by means of blasting, has typical feed sizes of up to 1200mm, with some even larger. Feed material is transported by truck to the 30m3 feed hopper of the 24.5m long KF 1500 chain conveyor, which conveys the material to the HCS 1020 primary sizer. The crushed fraction, with maximum size of 250mm, is then transported via two belt conveyors to the secondary crushing plant. Permanent magnets and a metal detector on the second conveyor protect against metallic foreign bodies entering the process.
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TRANSFER OF TECHNOLOGY At the secondary crushing plant, material is prescreened in the HAZEMAG 3-stage roller screen. The first and second screening stage separates out the < 12mm fraction from the material flow. This fraction passes to a reversing belt conveyor for transfer to a stockpile in the winter months or, during the summer, directly for use as an endproduct. The flowability of this screened material in winter is ensured by use of a downstream storage silo. In the third screening stage, the gap setting is 70mm â&#x20AC;&#x201C; the resulting oversize material of 70mm to 250mm is crushed in the HCS 0820 secondary sizer, to the target fraction of < 70mm, then conveyed to the downstream finishing process. The pre-screening process significantly reduces the quantity of secondary feed, avoids any unnecessary crushing, and minimises the size of secondary crusher required for the process. The contract was successfully completed in just 8 months, with commissioning taking place in November 2012. And, as contracted, HAZEMAG supplied all the plant components, the steel construction, engineering for the foundations, as well as installation and commissioning of the equipment. With this installation HAZEMAG fully demonstrated its strength in planning and implementing complete and intelligent processing plants.
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Material --> Dolomite: Feed size primary sizer Product size primary sizer Screening after primary sizer Feed size secondary sizer Product size secondary sizer Plant design capacity
0 - 800 x 800 x 500 mm 0 - 250 mm 0 - 12 mm, 12 - 70 mm 70 - 250 mm 0 - 70 mm plus some oversize 600 t/h
FOR MORE INFORMATION AND CONTACT: HAZEMAG & EPR GmbH Brokweg 75 48249 DĂźlmen | Germany Tel.: +49 (0) 25 94 77 - 0 Fax: +49 (0) 25 94 77 - 400 eMail: info@hazemag.de Internet: www.hazemag-group.com
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TRANSFER OF TECHNOLOGY
ContiTech Conveyor Belt Group | Phone +49 5551 702-207 transportbandsysteme@cbg.contitech.de
Please have a look at our social media service:
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NEWS & REPORTS SBM Mineral Processing GmbH
Clear design, simple operation and focussed on the essentials – that’s the new web presence of SBM Mineral Processing.
New Web Presence for SBM SBM Mineral Processing launches a brand new website. The upwards trend at the Upper Austrian specialist for machinery and plants, the expansion of the concrete mixing plants product portfolio and the integration of the brand „MFL-Mineral Processing“ have not only boosted the company alone. They also brought a fresh breeze to its web presence.
New Web Presence A lot has happened at SBM Mineral Processing. The brand MFL Mineral Processing was integrated into the company SBM and the division Concrete Mixing Plants was enlarged to a full-package supplier for mobile and stationary concrete mixing plants. So it was time to get fit for the future at www.sbm-mp.at as well. Clear and straight design, simple operation and focussing on the essentials were the preconditions for conception and implementation. Menu navigation ensures simple orientation and is focussed on the product fields Mineral Processing, Concrete Mixing Plants and After Sales without any detours. Information on global distributors and upcoming trade fairs are only a click away. Graphic conversion and programming were carried out by the Austrian creative company Friedrich Scheichl, www.friedrichscheichl.com.
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Just click www.sbm-mp.at if you want to see for yourselves.
SBM Mineral Processing GmbH SBM Mineral Processing has specialised in mineral processing plants and conveying plants for the natural stones and recycling industries for more than 60 years. In the business field mineral processing, SBM carries the brands SBM and MFL. The second business field of the Austrian high-quality manufacturer are mobile and stationary concrete mixing plants fulfilling all demands on international concrete standards. SBM has 130 employees and belongs to the globally acting MFL Group. FOR MORE INFORMATION AND CONTACT: SBM Mineral Processing GmbH Alexandra Wagner Head Marketing Oberweis 401 | 4664 Oberweis | Austria Tel.: +43 3612/270-1510 | Mobile: +43 676/8827-1510 eMail: a.wagner@mfl.at | Internet: www.sbm-mp.at
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NEWS & REPORTS
4. Deutsche Anlegermesse!
„Stock Day Report“ | Value Relations GmbH Frankfurt am Main | Deutschland
new record for the 4th Deutschen Anlegermesse 2013 in Frankfurt
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s the host of the fair Value Relations GmbH is pleased to announce a new record attendance for the third year in a row. While 5,000 guests were counted in 2012, this year almost 5,700 guests found their way to the fair. This is an increase of 13 percent. „It is a great success for us and the whole team of this investor fair. Again in this year we have given our eye teeth to offer our guests a great event. And if you have a look at the number of visitors we did a good job”, stated Sebastian Duernagel, project manager of the 4th Deutsche Anlegermesse Frankfurt.
4th Deutsche Anlegermesse 2013 Top-class guests from various sectors and finance experts ensured a good mood among exhibitors and visitors: Joachim Llambi, Michel Friedman, Bärbel Schäfer, Rita Süssmuth, Christoph Brüning, Holger Scholze, Bernhard Jünemann, Hermann Kutzer, Mick Knauff, Raimund Brichta, Dirk Müller and many others awaited the visitors on both days at Forum Messe Frankfurt. The Deutsche Anlegermesse is the biggest financial fair in the Rhine-Main-area. More than 150 exhibitors and partners presented their themes and products. With a total of 15 theme parks Deutsche Anlegermesse offered for experts and laymen enlightening information and interesting topics to talk about. The exhibitors praised the high number of professional visitors. Another highlight of the fair was the performance by NWM Mining which was presented by the CEO Chris Berlet in form of an interview. On Saturday afternoon almost 100 investors could be found at the second largest stage. The 30 minutes presentation was immediately followed by conversations at NWM´s booth in the hall. All this shows that investors are still interested in gold and gold shares. It becomes clear that there is a slowdown on demand of risky investments. Because of that and the fact that NWM has been producing since almost two years, NWM reflected precisely the interests of the visitors.
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At the charity gala the first night of the fair in total 3,000 € were collected. 300 guests contributed to a good cause through their generous donations and their buying of many raffle tickets with which they were able to win donated prices. The proceeds from the raffle held are completely going to the “Frankfurter Tafel e. V”. and “Ein Herz für Kinder”. “Deutsche Anlegermesse is now definitely established in Frankfurt and has become a fixed date for all important financial service providers not only from the banking metropolis but also from all over Germany and even abroad. “Again our visitors were totally pleased with the fair and the raise of almost 700 guests shows us, that the need of information as well as transparent and up front discussions about the topics of financial markets is still there”, stated Sebastian Duernagel. Next year the 5th Deutsche Anlegermesse Frankfurt will take place on 21st and 22nd February 2014 at Forum Messe Frankfurt.
„Stock Day Report“ Editor: Value Relations GmbH Gartenstraße 46 D-60596 Frankfurt am Main Tel.: +49 (69) 9592 46-0 Fax: +49 (69) 9592 46-20
Editorial: Christoph Brüning Internet: www.stockdayreport.de
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NEWS & REPORTS
Stock Week Spring 2013:
„Stock Day Report“ | Value Relations GmbH Frankfurt am Main | Deutschland
Four Companies – Four Cities – Four results
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n Monday the 22nd of April we planned to meet with the participating companies in Frankfurt respectively Cologne to talk about the final details of our Stock Week. Unfortunately Lufthansa stroke that day so that Mr. Paul Saxton, CEO and President of Lincoln Mining, was not able to attain. My route was planned as a nonstop flight to Frankfurt and was changed to a route from Los Angeles to Washington and from there across the Atlantic to Frankfurt. After an 18 hours journey I finally arrived ...
Stock Week Spring 2013 This was not the only bad news for the investors and the host because only two weeks before the Stock Week started the management of 49 North Resources had to cancel its participation. The persistent price decline led to an awkward situation: The lenders had a subscription price of 70 cents; at 25 cents the bank would have been the absolute supervising shareholder which was never their intention. The bankers did not want to be subsidiary managers or mining engineers. Therefore they had to get together at the negotiation table to find a solution – obviously in that case no one was able to make it to the event in Germany and Switzerland. Those were the small disappointments. In Cologne the first location of Stock Week Spring 2013 was the hotel Excelsior Ernst, where 40 investors showed up. As always we were supported on site by the Xing city group “Xing Cologne”. The presenter of the group, Martin Mueller, held a guest commentary about “social media”. The event focused on the subject gold and its security. The highlight of the day was in fact the presentation of Avalon Rare Metals´ CEO, who commented on the completed feasibility study for the first time in Cologne. The present Avalon shareholders were enthused! In the afternoon some interviews were carried out before the bulk hit the road. As usual we went from Cologne to our second stop Zurich which has been an integral part within Stock Week for years. Since two years now we have been supported from our partner Wolfram Boehm. The setting made the hotel Dolder Grand in the mountains outside the city and the investors arrived numerously. In Zurich it was Chris Berlet (NWM Mining) who convinced the guests with his producing mine. A Swiss investor commented: “The Investors become very riskaverse what makes the producers more attractive.” The next stop was Munich. We were a little bit disappointed from the response in the Bavarian capital, since only twenty investors appeared to the presentations. The guest commentary of Mr. Jochen Stanzl (BörseGo AG) would have deserved a bigger audience. He started his presentation with
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NEWS & REPORTS a comment on the few guests. He said that only a few investors showed up was a sign, that they had reached the bottom. He congratulated those who showed up to their decision to participate in the event. His speech covered the themes gold price and main elements of chart techniques. Out of all the impression made was, that gold built up a solid base for which reason the market players can be optimistic.
Conclusion – The four bottom lines of Stock Week Spring 2013 The crowning final of Stock Week was Frankfurt where the German Deutsche Rohstoffmesse was spontaneously switched to a Stock Day because of a lack of interest shown by the exhibitors. 50 investors found their way to the Kameha Suite which is more an average result for the main metropolis. In Frankfurt it was also Avalon that came off well. Besides, Lincoln Mining surprised with their presentation and was able to convince the investors. The Stock Week Spring 2013 ended with a common dinner, after further interviews were conducted in the afternoon.
„Stock Day Report“ Editor: Value Relations GmbH Gartenstraße 46 D-60596 Frankfurt am Main Tel.: +49 (69) 9592 46-0 Fax: +49 (69) 9592 46-20 Editorial: Christoph Brüning Internet: www.stockdayreport.de
Conclusion of the Stock Week Spring 2013 1. We are close to rock bottom DThe valuation of the resource shares has extremely fallen during the last months. At the TSX Venture 90 percent of the shares are traded below 10 cents and the majority of these incorporated companies runs out of money because investors refuse further payments. “We reached the end of the summer sale. Now everything must be sold and we find snips of high quality at the rummage table. Even though this is not the absolute rock - bottom, we are very close to reaching.” C. Bruening.
2. Gold, silver and rare earth elements are still highly interesting The most interesting sectors are rare earth elements and gold, which is with its emotional effect and excellent liquidity still number one. Gold shares got punished twice: First of all they did not rise and then they fell with the others. This doesn`t really makes sense but it is the truth. Silver will remain the stepbrother and come along. The prices for rare earth elements went back to normal after the hype of the last three years. Here a bottom is built and especially the demand for the heavy rare earth elements will provide higher prices. The environment separated the wheat from the chaff and Avalon was able to even improve its position.
3. Gold built up a bottom The megatrend gold is unabated. Gold has coped the setback very well and built up a bottom. Between 1970 and 1980 the gold price increased by 2,400 percent. During this phase in total there were four corrections made by more than 12 percent (30 percent, 50 percent, 20 percent, and 12 percent). The biggest increase took place during the last two years. If this increase is being followed the biggest part in the rise of value is still to come and at the same time we have to expect further corrections. “We can be confident”, summed up Jochen Stanzl (BörseGo AG).
4. The wave of consolidation is rolling – royalty companies take their positions Not only the producers are securing companies with highly qualified deposits. And not only royalty companies are investing in projects or companies. In fact primarily companies with cash and cash flow are consolidating actively now. Currently private equity funds are entering the market in northern America because the company valuations build only a fraction of their brake up value or net present value. The companies are withdrawn from Stock Exchange and then privately financed. For example on Stock Week we became familiar with the acquisition of Auriga by NWM. NWM is positioning in order to reach its goal of becoming a producer of 100,000 ounces per year via investing four millions in shares. Auriga is holding investments of almost 50 millions and has a net price value of approximately 100 millions – very clever Mr. Berlet. Chris Berlet
Chris Berlet - NWM Mining Issue 02 | 2013
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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 | 2013
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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 Terex Corporation
NINE TEREX® CTT FLAT TOP TOWER CRANES FOR ONE NATION!
layes Sous Bois, France, June 7th, 2013 – Tower crane rental and service provider LOGA is currently operating nine Terex CTT Flat Top Tower Cranes as part of the construction of C the One Nation Paris project - in response to the needs of general construction company Spie SCGPM (Spie Batignolles Group).
The state-of-the-art One Nation outlet center jobsite situated in Plaisir on the western outskirts of Paris, covers an area of 24.000 m² (258,333 yd²), of which two levels will be underground. The project includes 140 luxurybranded home, sportswear and fashion clothing stores, four restaurants, a spa, and gardens under a glass-roofed canopy. Behind the scenes, the project involves the use of one hundred per cent recycled materials - notably glass, concrete, aluminum, steel and wood.
Delivering intensive performance on time The LOGA team chose eight Terex CTT 331-16T and one Terex CTT 231-10T flat top tower crane models to handle the intensive, heavy-lifting task of hoisting, placing and pouring the estimated 1.100 t (1,212 US t) of steel and 17.000m³ (600,340 ft³) of concrete required to complete the construction of the building’s framework. Due to the presence of a nearby airport, LOGA erected the cranes progressively between May and August last
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year and equipped them all with aircraft light signals. With heights ranging from 28,4 m (93.3 ft) to 50,2 m (165 ft), the cranes were erected free-standing on a base, or secured in concrete foundations, and configured with jibs ranging from 35 m to 60 m (115 to 197 ft) in length. The cranes’ heaviest lifting duties involve hoisting 15 m (49 ft) pre-cast concrete segments weighing up to 9 t (10 US t) each. Well into their 15 month mission, LOGA is operating all nine cranes together at a strong steady pace and according to schedule.
Capitalizing on innovative and energysaving resources Besides using recycled materials, the One Nation concept is also designed to operate with high energy efficiency. A first in France, a water loop will recuperate and redistribute the energy produced by a nearby computer data center to heat the outlet’s stores - without generating additional CO2 emissions or relying on additional energy
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NEWS & REPORTS sources. For additional energy efficiency, 14.000 m² (160.695 ft²) of photovoltaic panels will be installed on the roof of the building. The Center is expected to open on October 2013 and attract more than 5 million visitors during its first year.
About the Terex CTT Flat Top tower crane range The entire range of Terex CTT Flat Top Tower Cranes encompasses a total of 28 models with load moments ranging from 50 to 720 mt. All Terex Flat Top Tower Cranes are characterized by quality workmanship to provide reliable performance under continuous operation. In addition, easy maintenance access and integrated safety functions help reduce downtime to provide a high level of cost-effectiveness that is also furthered by the units’ ergonomic cabs, which enable crane operators to work safely and with less fatigue for long periods of time.
About LOGA Based in outer Paris, and operating with a strong partnership network across France and Europe-wide, tower crane rental specialists LOGA leverages 20 years of experience adapting to the constraints and imperatives of customers in the construction sector. Working behind the scenes, the LOGA team prides itself in the trust of more than 400 companies and some 2000 projects - from office, school and industrial buildings, to car-parks, civil engineering and major infrastructure projects, to which it strives to provide the same constant high level of reliable service. More information can be found at www.logalocation.com.
About Spie SCGPM (Spie Batignolles Group) Spie SCGPM, a general construction company and part of the Spie Batignolles Group, focuses its activity in the Paris Region on designing/constructing offices, shopping centers, hospitals and housing, including large-scale refurbishment projects in the center of Paris, such as Saint Lazare train station. For more information, see the website www.spiebatignolles.fr
About Terex FOR MORE INFORMATION AND CONTACT: Terex Corporation Agustin Dominguez Associate Marketing Manager Communication Tel.: + 49 / 6332 – 83 1023 eMail: Agustin.Dominguez@terex.com Internet: www.terrex.com
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Terex Corporation is a diversified global manufacturer of a broad range of equipment that is focused on delivering reliable, customer-driven solutions for many applications, including the construction, infrastructure, quarrying, mining, shipping, transportation, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms; Construction; Cranes; Material Handling & Port Solutions; and Materials Processing. Terex offers financial products and services to assist in the acquisition of equipment through Terex Financial Services. More information can be found at www.terex.com.
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NEWS & REPORTS Terex Corporation
DOUBLE DUTY - Two TerexÂŽ CC2800-1 Crawler Cranes Make Short Work of Hawkeye Wind Farm
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awkeye, Iowa, USA, April, 2013 â&#x20AC;&#x201C; As the United States marches toward energy independence, 2012 was a banner year for wind energy projects. According to the American Wind Energy Association (AWEA), wind energy projects throughout the country posted their strongest year in 2012, bringing online a record 13,124 MW of power in 26 states and Puerto Rico. In the fourth quarter alone, 8,380 MW were installed. By the end of the year, wind generated more than 60,000 MW of power.
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NEWS & REPORTS Recently, Developer RPM Access (RPMA), LLC of West Des Moines, with help of two Terex® CC2800-1 crawler Cranes, completed the Hawkeye Wind Farm project in rural Fayette County, Iowa. This was one of the installations contributing to the record-breaking year for the wind industry. Hawkeye’s 15 wind turbines generate enough power to provide for the needs of more than 12,000 typical family homes each year. More importantly, the clean energy source will save at least 60 tons of carbon dioxide, 360 tons of sulfur dioxide and nearly 225 tons of nitrogen oxide emissions.
(80 m) tall structures of just a few years ago, as there is a significant increase in wind shear between 262.5 and 328 ft (80 and 100 m) above ground level.
Model of Efficiency The volume of wind projects poses a double-edged sword for a relatively small developer like RPMA. On one hand, market demand for new wind turbine erection is strong. On the other, a limited supply of crane capacity makes scheduling turbine projects difficult.
The nimble Terex CC2800-1 crawler crane led the construction charge, which began in early July, by erecting the first three tower segments. These heavier base sections ranged in weight between 79.6 and 81.7 ton (72.2 and 74.1 t). After completing installation of these three base tower segments, the crawler crane was moved the 0.25 to 1 mi (0.4 to 1.6 km) to begin construction of the next tower base.
“Heavy lift cranes for turbine construction can be the project bottleneck,” explains Steve Dryden, president of RPMA. “Heavy lift contractors will typically complete the big jobs first,” leaving the smaller projects like Hawkeye waiting for a crane to become available.
The second, taller CC2800-1 followed closely behind to complete the turbine installation. This configuration was the workhorse of the project, lifting the top two tower segments, 300-ton (272-t) nacelle and 37.5-ton (34.0-t) blade/hub assembly.
RPMA has learned that efficiency is the key to getting heavy lift cranes like the Terex CC2800-1 at the jobsite when it’s needed. The company works with its contractors to maximize the number of lifting days for turbine erection. Prior to bringing in the heavy lifting equipment, Nordex USA, Inc. of Chicago, Ill. acted as the general contractor and started the project in November of 2011. The first projects were to develop the 4.2 mi (6.8 km) of access roads and install 11.8 mi (19.0 km) of underground cable.
This crawler crane can be quickly configured for wind turbine erection applications with only a few special components, which include reinforced main boom segments and a rigid luffing jib developed specifically with wind power-related applications in mind. Offering a 661 ton (600 t) maximum lift capacity at a 32 ft, 10 in (10 m) radius, the Terex CC2800-1 can erect 328 ft (100 m) turbines without the need of its Superlift system, which saves time with crane assembly and disassembly. This provided a great benefit to RPMA for this project.
The following April, crews began pouring 15 turbine foundations, which consisted of up to 605 yd3 (462.6 m3) of concrete. By the time the two CC2800-1 crawler cranes were ready to be brought on site, RPMA and Nordex made sure the infrastructure was in place, so the cranes were on site for as the shortest time period possible.
Two Better Than One The 328 ft (100 m) tall turbines were erected on an average one turbine every two to three days. Each turbine consisted of seven lifts: 5 tower segments; a nacelle consisting of a deck, generator, gearbox, and cooling and control equipment; and a blade and hub assembly. These tall turbines present more of a challenge than the 262.5 ft
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To combat this issue and expedite turbine tower construction, the cranes were configured differently. One CC2800-1 crawler crane was equipped with enough boom and full counterweight to successfully lift the upper two tower sections, nacelle and hub/blade assembly. The second, shorter crane configuration had just enough lattice boom installed in order to erect the first three tower segments to a total height of 203.4 ft (60 m).
According to Kevin Lehs, Hawkeye project manager for RPMA, “We had to traverse agricultural fields and cross over county and state highways,” which required the cranes to be partially dismantled at times to transport from tower to tower. “With proper planning, we were able to minimize this to twice, and we were very impressed at the speed of crane assembly and disassembly.” When the shorter of the two CC2800-1 cranes finished constructing the three base tower segments of the 15th and final turbine, crews reconfigured the crane with a longer boom, so that it could help to “top off” the turbines. This allowed both crawler cranes to work toward each other until construction of all turbines were completed.
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NEWS & REPORTS Within a month’s time, the turbines were finished, leaving Nordex USA to complete the final steps of the Hawkeye Wind Farm project. In October of 2012, commercial operation of the 36 MW wind farm commenced, bringing power to thousands in northeastern Iowa.
About the Terex CC2800-1 The Terex CC2800-1 lattice boom crawler crane can be converted from a standard crane to a special-purpose crane for wind turbine projects — and back — with only a few special components. These special components include specially reinforced main boom segments and a rigid luffing fly jib (LF2) with a length of 39, 78, or 118 ft (12, 24, or 36 m) that were developed specifically with wind power-related applications in mind. The crane’s rated lifting capacity is 661 tons (600 t) at a reach of 32 ft, 10 in (10 m), while its maximum load moment is 7,710 mt. The standard carrier is available in duo- or quadro-drive and a narrow-track (NT) version, the latter allowing the crane to move through 17.3 ft (5.3 m) wide roads. The narrow track kit can be used with either 3.9 ft (1.2 m) wide track pads for a smaller total width or 4.9 ft (1.5 m) wide track pads for reduced ground pressure. In addition, the crane can be supplied with a chassis designed for road travel. The basic machine, including all winches and the A-frame, can be transported within a 13.2 ton (12 t) axle load limit. The high level of flexibility provided by these options and features saves time and money during transportation, setup, and disassembly, providing for a high level of cost-effectiveness in the process. Moreover, the time-tested Terex® IC1 control system, featuring remote radio control capabilities, makes it possible to operate the Terex CC2800-1 easily, safely, and comfortably in virtually any operating condition.
About RPM Access, LLC RPM Access LLC (RPMA) is a leading developer of wind generation projects throughout the Midwest. RPMA’s primary business is the development, owning and operating of smaller scale, utility grade, wind generation in the Midwest. The company has developed over 716 MW of operating wind generation projects in Iowa, amounting to approximately 15% of the total installed wind capacity in Iowa. Currently RPMA is the owner and operator of the 41 MW Elk Wind Farm in Delaware County, 36 MW Hawkeye Wind Farm in Fayette County and 50 MW Rippey Wind Farm in Greene County. For more information on RPMA, visit www.rpmaccess.com.
About Terex Terex Corporation is a diversified global manufacturer of a broad range of equipment that is focused on delivering reliable, customer driven solutions for many applications, including the construction, infrastructure, quarrying, mining, shipping, transportation, refining, energy, utility and manufacturing industries. Terex reports in five business segments: Aerial Work Platforms; Construction; Cranes; Material Handling & Port Solutions; and Materials Processing. Terex offers financial products and services to assist in the acquisition of equipment through Terex Financial Services. More information can be found at www.terex.com
FOR MORE INFORMATION AND CONTACT: Terex Corporation Agustin Dominguez Associate Marketing Manager Communication Tel.: + 49 / 6332 – 83 1023 eMail: Agustin.Dominguez@terex.com Internet: www.terrex.com
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NEWS & REPORTS ContiTech AG
Know-how and Service Make for Global Success
• ContiTech Conveyor Belt Group presents new cost-effective and sustainable conveyor belt technologies • Leading the way in service with single-component bonding agent and MiningCalculator
The new MegaPipes from ContiTech have an external diameter of up to 900 mm. Thanks to their size, MegaPipes allow for twice the flow rates of conventional closedtrough belts. This makes it possible to use them to transport even crushed ore or bulky goods. (Photo: ContiTech)
New Cost-Effective and Sustainable Technologies Hanover, 2013. The ContiTech Conveyor Belt Group, technology leader for conveyor belts, is further bolstering its position as one of the leading manufacturers in the field. The company‘s success is based on the ongoing development of new products such as the MegaPipes or the CONTI LIGHTWEIGHT TECHNOLOGY and on first-class service. The latest service offering comes in the form of the MiningCalculator, a computer program that allows customers to compare the cost-effectiveness and CO2 footprint of different modes of mining transport. These services offer customers clear commercial advantages and are perfectly tailored to the specific requirements of the relevant industries. In this way, the conveyor belt manufacturer sets new standards in the market and creates additional added value: „Our conveyor belt technology offers key advantages for protection of the environment and climate – this also applies in particular to the challenges that we jointly surmount with our partners in industry,“ says Hans-Jürgen Duensing, head of the Conveyor Belt Group business unit.
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The ContiTech Conveyor Belt Group is setting new standards in the market with two innovative developments. Closed-trough belts are among the most challenging of conveyor belt designs. The new MegaPipes from ContiTech have an external diameter of up to 900 mm. Thanks to their size, MegaPipes allow for twice the flow rates of conventional closed-trough belts. This makes it possible to use them to transport even crushed ore or bulky goods. The system is ultra eco-friendly in that the conveyor belt wraps tubelike around the material being transported. As a result, chemicals and other hazardous substances no longer come into direct contact with the environment. Another important development in this business unit is CONTI LIGHTWEIGHT TECHNOLOGY. The weight reduction makes for cost-effective and sustainable operations. This new technology cuts up to 30 percent off the weight of a belt. It thus uses correspondingly fewer resources and reduces the drive energy required to operate the belt. „Our Conveyor Belt Group has managed to make a major
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NEWS & REPORTS contribution to sustainability,“ explains Hans-Jürgen Duensing. The CONTI LIGHTWEIGHT TECHNOLOGY can be incorporated into a wide range of belt types and components. A further focal point of the Conveyor Belt Group is in the area of heat-resistant belts. Conveyor belts designed specifically for the transportation of hot materials can thus withstand extremely high temperatures. The belt‘s innovative insulation layer – HeatControl – can reduce temperature penetration to the carcass by as much as 40°C, thereby providing protection from premature failure in the case of belts used to transport sizzling hot materials. This is an important consideration in reducing costs and servicing outlay.
Intelligent Service and Service Materials This business unit also has something new to offer customers in the service area. Developers at the ContiTech Conveyor Belt Group have, for example, introduced an innovation in bonding agent technology that revolutionizes the cold bonding of conveyor belts. In contrast to previous bonding agents, the new Conti Secur® PREMIUM, which is used in different application areas, has but a single component. For fitters, a single-component bonding agent offers two major advantages: As there is no need for an accelerator solution, potential dosage mistakes are avoided. What is more, every last drop of Conti Secur® PREMIUM can be used without the bonding agent soon starting to vulcanize in the container. These two factors make the bonding agent particularly reliable and costeffective. With the aid of the MiningCalculator, a computer-based development from the University of Clausthal-Zellerfeld, ContiTech has – as the first manufacturer anywhere in the world – an instrument at its disposal that allows it to compare cost-effectiveness and CO2 footprint for truck haulage, conveyor belt haulage and combinations of the two. As a result, ContiTech customers will, in the future, be able to directly plan not only the cost efficiency of their operations but also the eco-friendliness and resource
sustainability. „In my opinion, this is one of the best services we have been able to offer our customers in the mining sector to date,“ says Hans-Jürgen Duensing.
Recycling: Conveyor Belts That Give Materials a New Lease on Life Alongside mining, there are a number of other application fields where conveyor belts play an increasingly important role. TransConti® Slide belts are, for example, in use in the recycling industry. In waste sorting plants, these belts – which are resistant to oil and grease – transport old packaging to the individual processing stations. In addition to highlighting their functioning, Hans-Jürgen Duensing also emphasizes the size of the conveyor belts employed: „In plants of this type, we use a larger number of conveyor belts to ensure a smooth and trouble-free flow of materials and thus the strict separation by type of material. These belts may exceed a length of 1 km.“ At booth F18 in hall 6 of the Hannover Messe visitors can to see a model from this field of application. Next to this, the business unit is also presenting conveyor belt technologies for agricultural systems. These include SICON®, a special conveyor system that protects feed pellets from dirt and moisture during haulage, as well as CONTI® round-bale compressor belts, which are used on harvesters to ensure that round straw bales are evenly compacted.
FOR MORE INFORMATION AND CONTACT: Mario Töpfer Head of Technical Media Relations, ContiTech AG Vahrenwalder Straße 9 D-30165 Hanover Tel.: +49(0) 511 938-1304 Fax: +49(0) 511 938-1305 eMail: mario.toepfer@contitech.de Jens Fechner Director Market Communications,ContiTech AG Vahrenwalder Straße 9 D-30165 Hanover Tel.: +49(0) 511 938-14019 Fax: +49(0) 511 938-14025 eMail: jens.fechner@contitech.de
With sales of €32.7 billion in 2012, 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 more than 170,000 employees in 46 countries. The ContiTech division numbers among the leading suppliers of a host of technical rubber products and is a specialist in plastics technology. The division develops and produces functional parts, components, and systems for the automotive industry and other important industries. ContiTech has a workforce of approximately 28,000 employees. In 2012, it achieved sales of about €3.7 billion.
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NEWS & REPORTS
ContiTech Sets New Benchmarks with MegaPipe
ContiTech AG
• Outside diameters of up to 900 millimeter double flow rates • Transportation directly after the primary crusher possible • Paves way to new market segments
With MegaPipe, the ContiTech Conveyor Belt Group is establishing new standards in closed-trough belt technology. MegaPipe can offer diameters as wide as 900 millimeters. Standard brands do not exceed an external diameter of 700 millimeters. This development is being presented for the first time at bauma 2013. The larger diameter of the MegaPipe offers two significant advantages. Firstly, the larger belt width of up to 3,200 millimeters enables a significant increase in the capacity of conveyor systems by more than 100 percent compared with standard closed-trough belts. With its latest development, the ContiTech Conveyor Belt Group also provides an ideal product solution for transporting coarse-grained material. MegaPipes can handle material with an up to 50 percent larger lump size than conventional closed-trough belt systems. MegaPipes are available both as textile and steel cord conveyor belts. This allows for the best possible adaptation to long distances with curves as well as to the requirements of the material being conveyed.
Significant potential for minimizing expense DMegaPipe opens up completely new possibilities and application areas for closed-trough conveyors. While crushed mineral ores, rock or coal have to be laboriously reduced in size for transportation with standard closedtrough belts, MegaPipes enable transportation directly after the primary crusher. In opencast mining, it is even possible to dispense with the use of trucks in hauling material away for further processing. The conveyor belts can also be used in industry to transport coarse-grained material. According to Dr. Andrey Minkin, application engineer at the ContiTech Conveyor Belt Group: „As far as I know, no other product to date has possibilities of a comparable nature.“ The larger belt widths do not impact
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With an external diameter of up to 900 mm, the new MegaPipes double the flow rate of conventional closedtrough belts and enable transportation directly after the primary crusher. They are available as textile belts or steel cord belts. (Photo: ContiTech)
on the center distance of the closed-trough conveyor system. In theory, a center distance – and with it an entire length – of over ten kilometers can be achieved with a steel cord MegaPipe. This is the same as for conventional long-distance installations..
Eco-friendly and flexible Apart from the width of the belt, ContiTech closedthrough belts made from high-quality flexible material offer significant advantages when used to transport dusty material on complicated routes. While the angle of inclination on troughed conveyor belts does not generally exceed 20° – depending on the properties of the material – and curve radii remain very large, a closed-trough belt makes possible sharp 3D curve radii and angles of inclination of up to 35°, depending on the nature of the material hauled. The material is shielded from the environment during transport. This protects ash, cement, minerals, coal, rock parts, and similar material from external influences while at the same time ensuring that the conveyance operation is particularly eco-friendly and does not release dust into the environment. „This is so because the belt rolls up,“ explains Wolfgang Fischer, application engineer at the ContiTech Conveyor Belt Group. The outside edges of the belt overlap throughout the transportation operation. Only when taking up and delivering material do the closed-trough belts open up and assume the shape of a conventional conveyor belt.
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NEWS & REPORTS ContiTech AG
Versatile and Robust Conveyor Belts for Industrial Applications
• Heat-resistant conveyor belts withstand temperatures of up to 600°C • TransCord ultra flexible thanks to elastic steel cable • CON-MONTEX® and CON-BITEX® impress with low-stretch behavior • FLEXOWELL® and POCKETLIFT® set the trend in the field of steep conveying
Munich, 2013. Robust, flexible, and high-performance ContiTech conveyor belts offer diverse possibilities for use in industry. The conveyor belt specialists will present their broad range of products at bauma 2013, impressing visitors with innovative and trend-setting solutions. The highlights of the trade show include specially developed conveyor belts for transporting hot material, which are worldwide unique in this form. They can provide service at even extremely high material temperatures of up to 600°C – subject to the shape of the material, load duration, and the quality of the system. „We took a modular system as the basis for the new heat-resistant conveyor belts,“ says Frank Kantorek from Business Development at the ContiTech Conveyor Belt Group. „This means that the conveyor belts are assembled individually from different components, depending on the
type of application. This ensures tailor-made conveyor belt solutions.“ Combining specially matched materials guarantees optimum service life, even under the very highest temperatures. The new HEAT CONTROL insulating layer, for example, reduces temperature transfer from the surface to the conveyor belt carcass by up to 40°C. An integrated, ultra melt-resistant fabric layer made of basalt or glass offers protection against premature failure when transporting red-hot materials.
Thanks to the modular system, the heat-resistant conveyor belts can be assembled individually from different components depending on the type of application. (Photo: ContiTech)
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NEWS & REPORTS
The EPP textile conveyor belts CON-MONTEX® and CON-BITEX® are robust and have a long service life. (Photo: ContiTech)
Elastic steel cord conveyor belt for small-radius bends TransCord represents a new level of development in the realm of steel cord conveyor belts. The conveyor belt combines the properties of both steel cord and fabric belts and thus opens the door to an even broader range of applications. It is, for example, much more flexible than conventional steel cord conveyor belts, making it suitable for use on lines with much smaller curve radii. „Elastic cords are used for the TransCord. That means it is not as longitudinally stable as conventional steel cord conveyor belts,“ says Kantorek. The new TransCord conveyor belts can also be used in systems with relatively small pulley diameters. On such systems, other steel cord conveyor belts of the same strength quickly run up against their limits. The TransCord needs shy away from comparison with conventional fabric belts, either; on the contrary, it performs much better than fabric belts in terms of material impact and its stretch behavior is also superior. Conventional cords are used for the carcass, as are cords with more stretch. The hard rubber compounds on the cords ensure very good bonding of rubber and metal. „We manufacture the belt using a procedure that is actually more in line with manufacturing fabric belts,“ says Kantorek.
produced using the most varied of cover stock materials (normal qualities, ultra wear-resistant, temperatureresistant, flame resistant, partially oil- and greaseresistant).
Low stretch behavior proven in practice EA further innovative product solution by ContiTech are the EPP textile conveyor belts CON-MONTEX® and CON-BITEX®. Thanks to a special fabric consisting of straight chaining and filling threads, they are particularly robust. The EEP belts feature a compound carrier made of polyamide (P) between the transverse and vertical threads. „The fabric used for the EPP belt is just as strong as an EP belt, yet 15 to 20 percent lighter,“ says Kantorek. Furthermore, both belts are characterized by optimal running and troughing properties and extremely low stretch behavior, which has proven itself in day-to-day use in cement plants, for example. In this application area, EPP belts prove to require much less maintenance than conventional steel cord conveyor belts. It is much easier to take care of any maintenance and repair work – an important factor for cement plants.
„Nevertheless, TransCord is a genuine steel cord conveyor belt.“ All TransCord conveyor belts can be
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NEWS & REPORTS Setting the trend in the area of steep conveying ContiTech relies on trend-setting innovations in the area of steep and vertical conveying. These innovations include FLEXOWELL® conveyor belts that are designed for horizontal, steep-angle, and vertical transport of bulk materials of all kinds – from coarse coal and ore, rock, granular sand or fertilizer to grain. The particle size can vary from ultra-fine, floury matter to chunks up to 400 mm thick. Capacities of up to 6,000 metric tons per hour and lifting heights of up to 250 m are possible. The benefits for system operators include quick installation, fewer material transfer stations, long service life, reduced energy consumption, and eco-friendly handling. POCKETLIFT® is the only continuous conveyor system for stroke heights of up to 700 m and capacities of up to 6,000 t/h. The conveyor belts are a further-advanced version of the successful FLEXOWELL® technology; they are only used vertically, however. „Power transmission is achieved with the help of two narrow steel cord conveyor belts that are connected with stable triangle-shaped cross members,“ says application engineer Benedikt Nothelle, head of sales at the Conveyor Belt Group. The material transported is carried in fabric-reinforced rubber pouches. The pouches have a carrying capacity of up to 4,000 m³/h. Thanks to these characteristics, POCKETLIFT® numbers among the trend-setting solutions for steep and vertical conveying.
With sales of €32.7 billion in 2012, 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 more than 170,000 employees in 46 countries. The ContiTech division numbers among the leading suppliers of a host of technical rubber products and is a specialist in plastics technology. The division develops and produces functional parts, components, and systems for the automotive industry and other important industries. ContiTech has a workforce of approximately 28,000 employees. In 2012, it achieved sales of about €3.7 billion.
The conveyor belt combines the properties of both steel cable and fabric belts and thus opens the door to an even broader range of applications. (Photo: ContiTech)
FOR MORE INFORMATION AND CONTACT: Mario Töpfer Head of Technical Media Relations, ContiTech AG Vahrenwalder Straße 9 D-30165 Hanover Tel.: +49(0) 511 938-1304 Fax: +49(0) 511 938-1305 eMail: mario.toepfer@contitech.de Jens Fechner Director Market Communications,ContiTech AG Vahrenwalder Straße 9 D-30165 Hanover Tel.: +49(0) 511 938-14019 Fax: +49(0) 511 938-14025 eMail: jens.fechner@contitech.de
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NEWS & REPORTS Phoenix Conveyor Belt Systems GmbH
PHOENIX Electronic Monitoring System Offers Revolutionary Technology
• PHOENOGUARD® PX for Enhanced Conveyor Belt Safety • Completely autonomous system permanently detects all conveyor belt damage and irregularities while belt is in use
The revolutionary PHOENOGUARD® PX constantly monitors the conveyor belt and detects all internal and external damages. (Photo: Phoenix Conveyor Belt Systems GmbH)
Hamburg/Munich, 2013. Conveyor belts are subjected to very high demands, especially in minerals mining. The constant impact of bulk goods during loading operations places major demands on the material. Sharp-edged objects can damage the conveyor belt, resulting in a need for costly repairs or even making it necessary to decommission the belt. With the PHOENOGUARD® PX, PHOENIX Conveyor Belt Systems has now come up with a revolutionary technology that permanently monitors the conveyor belt and detects all internal and external damage.
Intelligent control through PHOENOGUARD® PX From notching on the covers to penetration of foreign bodies and damaged steel cords, this unprecedented new development not only records the current status
The completely autonomous PHOENOGUARD® PX was being presented for the first time at bauma 2013. It was this year‘s trade fair highlight from PHOENIX Conveyor Belt Systems. From notching of the cover stock to damaged steel cords – the PHOENOGUARD® PX records the conveyor belt’s actual condition. Should an emergency arise, it automatically intervenes in the operation of the system. (Photo: Phoenix Conveyor Belt Systems GmbH)
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NEWS & REPORTS of the conveyor belt, but also intervenes automatically in the operation of the system in an emergency. If the system identifies damage that could result in failure of the conveyor belt system, PHOENOGUARD® PX immediately shuts the operating system down. In the case of minor hole damage with no direct impact on the condition of the conveyor belt, the system triggers an alarm. A unique method makes targeted intervention of this kind possible: Without any contact at all, the system registers every cubic millimeter of the conveyor belt. At the same time, all surface characteristics are stored in a database and the damage is classified and categorized according to extent and other criteria. The PHOENOGUARD® PX permanently compares these saved surface characteristics with the current status. This allows the PHOENOGUARD® PX to precisely judge any fresh damage occurring. It can then make targeted intervention to prevent damage from occurring.
PHOENOGUARD® PX: focus on individuality and cost minimization Customized filtering enables users to adjust the settings as needed. If users want to capture an image of the conveyor belt‘s current status themselves, they can do so at the click of a mouse. The PHOENOGUARD® PX provides a comprehensive digital snapshot of the belt. This images not only major damage and incorrect conveyor belt orientation but also smaller tears or gaps. With holistic imaging and monitoring of this nature, the PHOENOGUARD® PX reduces the work and cost of maintenance. Production downtime can be avoided by means of preventive action that precludes unplanned closure of the facility due for lengthy repair work. The PHOENOGUARD® PX is virtually maintenance-free.
A click of the mouse is all it takes to trigger a PHOENOGUARD® PX digital snapshot image of the conveyor belt. (Photo: Phoenix Conveyor Belt Systems GmbH)
FOR MORE INFORMATION AND CONTACT: Bernd Küsel Phoenix Conveyor Belt Systems GmbH Hannoversche Straße 88 21079 Hamburg Tel.: +49 (0)40 7667 2205 Fax: +49 (0)40 7667 2411 eMail: bernd.kuesel@phoenix-cbs.com Internet: www.phoenix-cbs.com
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NEWS & REPORTS Phoenix Conveyor Belt Systems GmbH
Heat-Resistant Conveyor Belts from PHOENIX Now Good Up to 300°C
• MAGMA EXTREME heat-resistant conveyor belt for temperatures up to 300°C • PHOENOTEC® protects conveyor belts from damage • PHOENIX S-Wall™ belt with corrugated sidewalls overcomes Gradients up to 90°
Hamburg/Munich, 2013. At bauma, PHOENIX Conveyor Belt Systems was for the first time presenting the MAGMA EXTREME conveyor belt, a logical addition to the existing range of heat-resistant conveyor belts. Thanks to a more temperature-resistant cover stock – manufactured using a newly developed compound – MAGMA EXTREME can withstand even temperatures as high as 300°C. This property makes the new development ideal for temperature-intensive application areas such as are found in the cement industry. PHOENIX Conveyor Belt has suitable conveyor belt systems for other industrial areas and applications, too. To ensure this, the conveyor belt specialist is constantly expanding its product range. At bauma, the focus was on product solutions in the fields of heat-resistant conveyor belts and belts with corrugated sidewalls for steep conveying. It is also addressing the subject of cost minimization by means of conveyor belt protection systems.
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The conveyor belt protection system PHOENOTEC® offers active protection from damage caused by objects impacting on the conveyor belt from a considerable height or by sharp objects. (Photo: Phoenix Conveyor Belt Systems GmbH)
Minimized costs thanks to a conveyor belt protection system The active conveyor belt protection system PHOENOTEC® is proving particularly useful for many industrial applications. The system consists essentially of special polyamide cords that can optionally be integrated into the conveyor belt cover stock for the sake of transverse reinforcement. These features make the conveyor belt significantly less vulnerable to impact damage and slitting while at the same time retaining the belt‘s good troughability. PHOENOTEC® thus extends the service life of the conveyor belt and minimizes accident-related repair costs.
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NEWS & REPORTS
New steep-angle conveyor belts overcome 90-degree inclines The whole breadth of PHOENIX S-Wall™ corrugated sidewall belts was also displayed at bauma. PHOENIX is expanding its range with the addition of these stateof-the-art steep-angle and vertical conveyor belts. The greatest advantage of this system: Transfer points are no longer required. This helps, in turn, to minimize spillage. The system also allows for maximum exploitation of the available clearance. This is particularly important where space is at a premium. PHOENIX has added a new hot vulcanization process as an alternative to conventional cold-bonding. By means of heat and pressure, the sidewalls and cleats are vulcanized into the basic belt, creating a particularly strong bond. Conveyor belts manufactured in this way can be used both at higher ambient temperatures and under extreme loads. This long-lasting and durable bonding method considerably extends the service life of the conveyor belt, while, at the same time, reducing maintenance costs in the case of special applications.
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Thanks to a temperature-resistant cover plate, the new MAGMA EXTREME heat-resistant conveyor belt can withstand even temperatures as high as 300°C. (Photo: Phoenix Conveyor Belt Systems GmbH)
FOR MORE INFORMATION AND CONTACT: Thorsten Mendt Phoenix Conveyor Belt Systems GmbH Hannoversche Straße 88 21079 Hamburg Tel.: +49 (0)40 7667 2251 Fax: +49 (0)40 7667 2411 eMail: thorsten.mendt@phoenix-cbs.com Internet: www.phoenix-cbs.com
Tom Webster Specialised Belting Solutions Ltd. Unit 26-32 Brunel Way Thetford, Norfolk, UK, IP24 1HZ Tel.: +44 (0)1842 754392 Fax: +44 (0)1842 765264 eMail: tom.webster@phoenix-cbs.com Internet: www.sbsbelting.com
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NEWS & REPORTS ThyssenKrupp AG
CO2 emissions, energy costs, noise, and water consumption all reduced
INTEGRATED SKIP CONVEYING AND CRUSHING SYSTEM
ThyssenKrupp Resource Technologies sets standards in open-pit mining and cement production:
A
t BAUMA 2013 ThyssenKrupp Resource Technologies had showcased its capabilities as an innovative system supplier for the mining and cement industries. The new engineering company, created by the merger of ThyssenKrupp Fördertechnik and ThyssenKrupp Polysius, develops “better” solutions that offer “more” value for our customers. .
Integrated Skip Conveying and Crushing System – going up Open-pit hard rock mines extracting iron ore and other materials use huge monster trucks weighing up to 260 tons and carrying payloads up to 400 tons. The world’s largest mines use dozens of such vehicles. The investment costs, fuel consumption and associated CO2 emissions are immense. With its INTEGRATED SKIP CONVEYING AND CRUSHING SYSTEM, ThyssenKrupp Resource Technologies offers a sustainable and cost-effective alternative. Unlike in truck haulage, where not only the payload but also the deadweight of the truck has to be moved, the
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INTEGRATED SKIP CONVEYING AND CRUSHING SYSTEM only uses energy to transport the payload. The reason for this lies in the special design of the system, which ensures that the deadweights of the skips balance each other out. Two skips are connected by a common rope sheave drive system and can convey a complete truck load on rails from the loading station to the crusher at the top of the mine, using the shortest possible route over gradients of up to 75 degrees. Further transportation of the material from the crusher can then be carried out efficiently by belt conveyors. The advantages of the INTEGRATED SKIP CONVEYING AND CRUSHING SYSTEM over conventional truck haulage are considerable: For example, in a mine with a capacity of
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NEWS & REPORTS 2,700 tons of ore per hour and a vertical rise of 200 meters covered by seven 250 ton trucks traveling a distance of 2,500 meters up an eight percent gradient, CO2 emissions were reduced by 29 tons per day! Mine haulage costs are 50 percent lower, and noise and dust pollution are also reduced. A further advantage of the INTEGRATED SKIP CONVEYING AND CRUSHING SYSTEM is increased availability: Operation is not impeded by bad weather conditions. Last but not least are the economic advantages for the mine operator. Use of the INTEGRATED SKIP CONVEYING AND CRUSHING SYSTEM reduces operating and labor costs as well as investment in the truck flee.
POLAB ® Shuttle - New generation of laboratory automation systems The POLAB® Shuttle is a laboratory automation system offering unique flexibility. It has already proven its value in the laboratories of several cement producers, and further orders have been received. Sample handling by means of a mobile robot enables unprecedented flexibility in terms of configuration, expandability and room layout. Operating on rails, the mobile robot serves the individual modules including pneumatic tube receiving station, sample preparation, sample return, input/output magazines and analyzers.
Thanks to the innovative safety concept the laboratory becomes a shared workspace for humans and machines. The laboratory is barrier-free and the individual components can be operated both automatically (by the mobile robot) and manually. The concept makes it possible to create laboratories offering full redundancy, maximum availability and very high sample throughput rates.
ThyssenKrupp AG A full range of specialist engineering and construction services and a shipbuilding history stretching back centuries are the strengths of the Industrial Solutions business area. High-quality engineering is at the center of our success. Global project management skills, firstclass system integration expertise, reliable procurement and supplier management, and a service offering meeting the highest standards form the basis for lasting customer satisfaction. 20,000 employees at over 70 locations form a global network with a technology portfolio that guarantees maximum productivity and cost-efficiency.
FOR MORE INFORMATION AND CONTACT: ThyssenKrupp AG Cosima Rauner, Corporate Communications Hannoversche Straße 88 21079 Hamburg Tel.: +49 (0)201 844 553249 Fax: +49 (0)201 844 553249 eMail: cosima.rauner@thyssenkrupp.com Internet: www.thyssenkrupp.com
POLAB
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NEWS & REPORTS ThyssenKrupp AG
ThyssenKrupp Resource Technologies – achieving more together
Plant for cement production
Innovative solutions for the minerals, mining and cement industries :
A
s part of ThyssenKrupp’s strategic development program the two engineering subsidiaries ThyssenKrupp Fördertechnik and ThyssenKrupp Polysius are being merged with effect from April 02, 2013 to form ThyssenKrupp Resource Technologies. With around 5,500 employees and annual sales of approx. two billion euros, the new company will be one of the world’s leading system suppliers for the mining and cement industries as well as the mineral processing and bulk materials handling sectors. It will offer single-source expertise ranging from design and consulting to engineering and project management to construction and installation, after-sales service, research & development and plant financing. Dr. Hans Christoph Atzpodien, CEO of the Industrial Solutions business area of ThyssenKrupp AG, on the strengths of the new company: “As a strong cornerstone of the Industrial Solutions business area, ThyssenKrupp Resource Technologies will have a presence on the world’s growth markets. Our comprehensive engineering know-how covers solutions from single machines to complete plants. With growing environmental awareness and rising raw material and energy prices, this engineering expertise provides our customers with a significant competitive edge.
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With “better” solutions we will create “more” value, for example by cutting operating costs and reducing CO2 emissions.” The management board of ThyssenKrupp Resource Technologies is made up of Ramsis Shehata (CEO), Christof Brewka (service business), Heike Franke (CFO), Martin Hilbig (CHRO) and Lothar Jungemann (cement business). ThyssenKrupp Resource Technologies has an extensive global sales and service network. Its fast-growing service operations are being systematically expanded. The
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NEWS & REPORTS ThyssenKrupp Resource Technologies product range includes bucket-wheel excavators, conveyor systems, crusher plants, grinding and processing plants, stockyard and port handling systems for bulk materials as well as cement plants. Lifecycle support can be provided for all products, as well as 24/7 service for individual machines or plants.
Plant for the processing of copper ore
ThyssenKrupp AG A full range of specialist engineering and construction services and a shipbuilding history stretching back centuries are the strengths of the Industrial Solutions business area. High-quality engineering is at the center of our success. Global project management skills, firstclass system integration expertise, reliable procurement and supplier management, and a service offering meeting the highest standards form the basis for lasting customer satisfaction. 20,000 employees at over 70 locations form a global network with a technology portfolio that guarantees maximum productivity and costefficiency.
FOR MORE INFORMATION AND CONTACT: ThyssenKrupp AG Cosima Rauner, Corporate Communications Hannoversche StraĂ&#x;e 88 21079 Hamburg Tel.: +49 (0)201 844 553249 Fax: +49 (0)201 844 553249 eMail: cosima.rauner@thyssenkrupp.com Internet: www.thyssenkrupp.com
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NEWS & REPORTS BEUMER Group GmbH & Co. KG
Customized system solutions for the bulk materials industry: From component supplier to main contractor!
Bulk materials can be transported quickly and efficiently from the excavation point to their destination, even over impassable terrain.
T
he ever increasing technical demands in the bulk materials industry are reflected in the particular expectations of the user. Manufacturers who not only supply everything from one source but also undertake the complete project to the point of turnkey handover are in demand. The Beckum-based BEUMER Group with affiliations around the globe develops customized system solutions for conveying and loading, palletizing and packaging, and sortation and distribution systems. BEUMER also acts as the main contractor on behalf of its customers. “A significant trend is that more and more clients want to commission their systems in a turnkey state,” says Dr. Gerd Oberheuser, Head of System Technology at the BEUMER Group, regarding the increased market requirements. “Engineering, Procurement and Construction”, EPC, or EPCM – “Engineering, Procurement and Construction Management” – for short, are the buzzwords here. EPCM is an enhanced form of project management. “This trend can be seen in many parts of the bulk materials industry, for example in cement and opencast mining,” explains Dr. Oberheuser.
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Comprehensive portfolio for the bulk materials industry With the acquisition of Enexco Teknologies India Limited in 2011, the BEUMER Group has expanded its business activities in India and in doing so has strengthened its presence, particularly in the cement industry, in one of the world’s most important growth markets. For example, the portfolio includes horizontal and vertical belt conveyor systems, belt bucket elevators, heavy-duty bucket elevators for particularly large delivery rates and heights, and steel cell conveyors fitted with chains or belts for clinker.
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NEWS & REPORTS The intralogistics specialist also provides grinding mills, silos and systems for filling, palletizing, packaging and loading. As well as the cement and mining industry, BEUMER system solutions, such as belt conveyors, are also in increasing demand in the coal industry. The conveyor solutions are also used in the firing of power stations. These are also more and more frequently heated with environmentally compatible fuels such as wood pellets, shredded tires and waste. BEUMER supplies suitable systems for transporting the fuels to the boiler, for example.
Changed conditions “For a quotation to be accepted, contracts are often only placed on an EPC basis,” remarks Dr. Oberheuser. This means that, as well as supplying the equipment, BEUMER is responsible for the whole process. This includes the design of the entire system, the installation, the commissioning and the instruction of subcontractors. Not only does a high availability of machines and systems play a decisive role, but also optimum support. For this reason, BEUMER has set up competence centers in the Czech Republic, in Austria, at its headquarters in Beckum, and in North America. These take care of research and development, sales, project management and purchasing.
With its solutions, the BEUMER Group helps users to work more cost effectively and in a more environmentally friendly manner. BEUMER belt conveyors enable companies to transport large quantities of bulk material from the quarry or mine to the factory or port as cost effectively and as quickly as possible. Trucks have considerable disadvantages in this regard. Road building is expensive, and the more raw materials have to be transported from the excavation point to the factory, the more journeys have to be made. Added to this are the operating costs and emissions caused by trucks – both with regard to fuel consumption and personnel costs as well as noise and dust. As a result of the direct route, the material is transported much faster than by truck. In addition, belt conveyors can be operated with significantly fewer personnel. Another aspect compared with trucks is the lower energy consumption, which at the same time reduces CO2 emissions. Depending on the project, belt conveying systems need up to 90 percent less primary energy than comparable truck transportation.
Cost-effective and environmentally friendly conveying Belt conveyors can overcome long distances, steep gradients and tight curves, and can be individually matched to the particular task and topography. Use is made of durable, tension-resistant conveyor belts. In doing so BEUMER uses various calculation programs to determine In the difficult terrain, the transportation of bulk materials by truck would require significant detours, extend transport times and substantially increase costs.
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NEWS & REPORTS the optimum belt design. These enable tensile forces to be analyzed and also forces which occur due to acceleration and deceleration – always taking into account the intrinsic weight of the belt and the transported material. They are also used to determine possible curve radii. BEUMER also provides advance feasibility studies. In addition, the belt position is calculated in advance with the appropriate curve radius for the empty and loaded states.
a conveyor with a length of 3.48 kilometers for a large mining concern. This will convey up to 6,000 tonnes of iron ore per hour. This large-area conveyor system must withstand extreme temperatures of down to -40 degrees and heavy snowfalls. BEUMER has designed all mechanical and structural elements for the extremely low temperatures. For example, the system is fitted with a feed conveyor and an unloading system with tripper car.
With their slender lines, belt conveyors overcome broken terrain and other obstacles such as rivers, roads, buildings or rail tracks. Horizontal and vertical curves in the routing can also be overlapped. Depending on the requirement, BEUMER offers open troughed belt conveyors for higher throughputs and larger mass flows as well as larger curve radii, and enclosed pipe conveyors for products which need to be protected against the effects of the environment.
As main contractor, BEUMER is equipping a new distribution center off the shore of Malaysia with 17 trough belt conveyors with a total length of twelve kilometers for a large iron ore exporter. The conveyors will ensure swift transport of iron ore from super-size freighters to the mainland. BEUMER will deliver and install the conveyors, put them into operation and take full charge of engineering, all according to a strict timetable.
At the port of Callao in Peru, BEUMER will be installing pipe conveyors with a length of around three kilometers for transporting copper, lead and zinc concentrates for completion in 2014. “Depending on the landscape and environmental conditions, we can install overland conveyors with horizontal curves with lengths of up to 20 kilometers,” explains Dr. Oberheuser. Gradients of up to 15 degrees can be realized depending on the characteristics of the materials to be conveyed. After planning, installation and commissioning, maintenance and service are no more laborious than with a straight conveyor. On average, the annual maintenance costs are only around 2% of the investment sum. In Canada, BEUMER is currently installing
FOR MORE INFORMATION AND CONTACT: BEUMER Group GmbH & Co. KG Oelder Str. 40 59269 Beckum | Germany Internet: www.beumergroup.com Regina Schnathmann Tel. + 49 (0) 2521 24 381 Regina.Schnathmann@beumergroup.com Verena Breuer Tel. + 49 (0) 2521 24 317 Verena.Breuer@beumergroup.com
About BEUMER Group
Belt conveyors will transport iron ore from the terminal to the port located three kilometers away. (Photo: Vale)
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The BEUMER Group is an international leader in the manufacture of intralogistics systems for conveying, loading, palletising, packaging, sortation and distribution technology. Together with Crisplant a/s and Enexco Teknologies India Limited, the BEUMER Group employs about 3,200 people and achieves an annual turnover of about 500 million EUR. With its subsidiaries and sales agencies, the BEUMER Group is present in many industries the world over. For further information visit www.beumergroup.com.
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NEWS & REPORTS Metso Global | www.metso.com
Metso Global: Increased production and energy efficiency for optimized Antamina mine
ompañía Minera Antamina’s collaboration with Metso was so successful that the Peruvian mine is now consistently exceeding their demanding production targets and at the same C time minimizing energy consumption per ton of product. Metso Process Technology and Innovation (PTI) has assisted Compañía Minera Antamina to increase its mill throughput by integrating and optimizing blast fragmentation, crushing and grinding operations. So successful was this collaboration that Antamina is now consistently exceeding their demanding production targets and at the same time minimizing energy consumption per ton of product when processing hard copper and zinc ores. The advent of harder ores presented a problem for the Peruvian mine, but Antamina technical and management staff worked with Metso PTI, and following the initial optimization of operating strategies in the mine and plant, mill throughput while treating hard ores increased from 2,750 tph to reach an average of 3,600 tph. Continued application of the Process Integration and Optimization (PIO) philosophy and methodology delivered further improvements and ensured that the concentrator consistently exceeded the target of 4,400 tph while processing harder ores. The significant increase in throughput and optimization of the overall production system also considerably improved the energy efficiency of the operation, resulting in less energy consumption per ton of product.
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Harder ores as a challenge The Antamina mine, which commenced operation in 2001, had achieved its designed capacity of 70,000 tpd after five months of operation when treating copper ores (M1/ M2). However, there were several issues associated with the treatment of harder copper/zinc ores (M4/M4A), which limited the throughput for these ore types to just half of the M1/M2 throughputs (i.e. 2,000–2,500 tph versus 4,000– 5,000 tph). Achieving similar throughputs for both ore types became a challenge for Antamina. Metso Process Technology & Innovation (PTI) was approached by Antamina to assist in increasing the throughput of the difficult ores through the implementation of a Process Integration and Optimization (PIO) project. Metso’s Process Integration and Optimization (PIO) involves the development of integrated operating and control strategies from the mine to the plant that maximize throughput, minimize overall cost per ton, minimize energy consumption and maximize profitability. This methodology utilizes a combination of geological, geotechnical and quantitative information on ore petrophysical and comminution characteristics.
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NEWS & REPORTS
Metso Global: Restarting a mine requires a strong service partner
Metso Global | www.metso.com
Buena Vista del Cobre mine in Mexico is back in action after three years of inactivity. Metso played a key part in the process, and is now opening a service hub to support the expanding mine. After three years of inactivity, the Buena Vista del Cobre mine in Cananea, Sonora, Mexico, has been operational since 2010. A mine that was inactive for such a significant amount of time, however, requires a great deal of support to successfully restart the plant and bring it back to an operational and profitable state. Following a large investment in Metso crushing equipment and services, Buena Vista del Cobre is now expanding the mine site to include even more equipment – and with that expansion comes the need for more local service resources. Metso and Buena Vista del Cobre have entered into a Life Cycle Service agreement for the plant, and construction of a brand new Metso service hub is underway in Cananea.
Establishing safety “It was key to have our support here in Cananea because the Buena Vista del Cobre started from the ground up,” says Felix Fornaguera, Director of Services, Mexico Central America and Caribbean. “We’ve been able to help the customer to establish the best in support, service and operations from the very beginning.” And this ground-up approach included a major focus on safety. Metso worked closely with Buena Vista del Cobre to establish the safety protocol by which the mine operates. Based on Metso’s expertise, the safety measures put in place have enabled the mine to become strict and efficient in its operations and maintenance procedures. To achieve this, Metso worked closely with local and national authorities to ensure the safety plan was comprehensive and in accordance with all established legal bodies.
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New facility, a new level of service The Metso Cananea service hub, which will be up and running in early 2013, will support the recent expansion and resurgence of Buena Vista del Cobre. Initially, it will be a major repair and assembly center for pumps, crushers and screens and will provide for rubber covering capabilities. But the 8,000-square-meter facility’s service offering will be expansive, including a consignment stock inventory, to help serve the mine’s varying needs. Metso currently has 50 service team members on site. Although Buena Vista del Cobre was a key influencer in building the new service hub, this location will also enable Metso to expand its capabilities and provide local support to the entire mining community in northwest Mexico. The Cananea hub will serve number of major copper and gold mines in the region, including Minera Frisco’s San Felipe, Fresnillo’s Milpillas and Grupo Mexico’s Mexicana de Cobre.
The best in regional support “We are the first company developing this kind of service (in northwest Mexico),” says Fornaguera. “Our people have developed a close relationship with the team at the mine: It’s more than a supplier relationship; our guys are inside the mine, living and working there.” In fact, this is the model that Metso is using in service hubs all over the globe: building modern facilities, bringing teams on site, and working hand in hand with mine operators. The Cananea Service Hub is only the most recent example of Metso’s commitment to service, and northwest Mexico is yet another mining hotbed that’s going to benefit from the company’s support.
Metso Global | www.metso.com
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NEWS & REPORTS Metso Global | www.metso.com
Metso Global: Big Lokotrack LT550GPF boosts quarrying productivity by a third
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aximizing the productivity of operations is a key issue when striving for cost-effective quarrying. Big Lokotracks are one way to achieve improved operational efficiency. The Lokotrack LT550GPF, equipped with the high-volume GP550 cone crusher and a large screen, is popular in the Nordic countries, and in Germany and Australia – countries all known for their high quarrying volumes.
“With the same number of employees, we can achieve 30% more productivity with our new LT550GPF unit. The high-capacity FS screen has also eliminated the bottleneck often seen at fine screening,” says Aarno Kostamo, Managing Director of Kone-Kostamo Oy, one of Finland’s biggest crushing contractors.
“The mobile process, consisting of the LT120 jaw plant and LT550GPF cone plant, is cost-effective, while aggregates of various sizes can be produced in a twostage operation and with high capacity. The controlled stroke and elliptical movement of the FS screen secure big passing through capacities,” Kostamo explains.
According to Kostamo, the high capacity of the GP550 gyratory cone crusher easily handles feed from the C120 and C125 jaw crushers. For the contract with the Talvivaara nickel mine, the LT550GPF is being fed by the brand new Lokotrack LT120 jaw plant.
Operated in two shifts for a total of 16 hours per day, the LT550GPF has logged more than 600 working hours over a two-month period.
Average capacity 300 tons per hour Talvivaara, Europe’s largest nickel mine, utilizes large quantities of aggregates. Kone-Kostamo has contracted several million tons of different end products for the mine. In August 2012, 75,000 tons of 0-63 mm road gravel was crushed. Smaller amounts of finer, 0-6 mm, 0-16 mm and 0-32 mm aggregates are also being produced. The rainy summer increased the need for road gravel along the muddy roads, which must endure dump trucks weighing as much as 260 tons.
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The customer: Founded in 1956, Kone-Kostamo
processes around 2.8 million tons of aggregates annually. “We believe that issues within the crushing industry, including the purchasing of machinery, must be studied with a longer perspective than a single quarter. The secret to our success has always been our solid work ethic and professional employees,” Aarno Kostamo sums up.
Metso Global | www.metso.com
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NEWS & REPORTS Different ore types are characterized and tracked through the entire process (mine to plant). It is crucial that the ores being fed to the mill are characterized in the mine and then tracked through the downstream processes. Metso PTI has developed an ore tracking system named SmartTag™ that allows parcels of ore to be tracked from the mine, through the crusher and finally into the grinding mills. The SmartTags™ are built around robust passive radio frequency transponders. They do not have an internal power source, so they can remain in stockpiles and ROM pads for extended periods of time. Antennas to detect the SmartTags™ are located at critical points in the process ahead of the milling circuit; tags can be detected a number of times and provide valuable information on material movements. In particular, they make it possible to link the spatial data associated with the ore in the mine to the time-based or temporal data of the concentrator. Integrated, site-specific operating and control strategies are developed for different ore types with the aid of field measurements, historical data, audits and surveys, calibrated site-specific models, simulations and site validation. This PIO methodology offers a cost-effective and rapid route to increased profitability through increased overall production, reduced energy consumption, higher metal recovery and better overall process operation and stabilization. The measurement techniques have been developed over many years to suit the mining environment; they are inexpensive and can be easily carried out by mine personnel. The defined integrated operating strategies are implemented and monitored using established standards, quality assurance and control mechanisms to ensure benefits are maintained in the long term.
Implementing PIO at Antamina Metso and Antamina personnel conducted a comprehensive review of existing operations at the mine and in the comminution circuits. Ore sources were characterized into domains of rock structure and strength with similar blastability and fragmentation properties. Blast design implementation, drill and blast QA/QC and the resulting fragmentation were measured in blasting audits along with vibration. These audits allowed benchmarking of existing practices in the mine and definition of main constraints related to wall stability, control, ore dilution and environmental aspects. Blasted material was tracked from the mine through the process using SmartTagTM ore tracking. Two antennas
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were installed at Antamina – one on the primary crusher product belt and another on the SAG mill feed belt – thus allowing the performance in the crushing and milling circuit to be linked to the ore characteristics and blast fragmentation measured during the audited blasts. Metso PTI and Antamina staff also analyzed historical data, reviewed the current operating practices of the primary crusher, the SAG and ball mill grinding circuits, and conducted a number of audits and surveys. These data were used to develop mathematical models of the drill and blasting, crushing and milling operations. These resulting site-specific models were linked and simulations were conducted to identify optimum operating strategies for the overall process. The proposed strategies were discussed and analyzed in detail with site technical staff. The optimal and most cost-effective integrated operating strategy for the entire process including mine and plant was then implemented in combination with other initiatives led by Antamina personnel.
Using integrated models and simulations The site-specific models for the blasting, crushing and grinding operations at Antamina were developed based on data collected on-site and samples taken from the mine and the plant before and during industrial trials. These models were linked to simulate the overall process. The inputs for these models include rock properties (strength and structure), blast design parameters (such as burden, spacing, stemming column and explosive type, quantity, etc.), primary crusher setting, SAG mill operating conditions and ball mill circuit conditions. The simulations at Antamina assisted site personnel to evaluate and establish optimum operating strategies and quantify the possible increases in throughput. Conditions such as different blast designs, primary crusher setting, SAG mill grate design, SAG mill ball charge level, ball mill operating conditions, changes in classification with hydrocyclones, use and operation of recycle/pebble crushers were all considered and evaluated in the simulations. The most cost-effective of these derived strategies were analyzed by a joint Antamina and Metso team and implemented on site. Following implementation of these strategies, the SAG mill throughput when treating the harder copper/zinc ores increased from 2,750 tph to an average of 3,600 tph, and the optimization of the overall process improved energy efficiency, resulting in considerably less energy consumption per ton of product.
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NEWS & REPORTS
Continuous improvement delivers further benefits After the initial success of the PIO project, Antamina and Metso PTI entered into a technical services support contract to refine and further improve the operation. Additional blast fragmentation improvement and its impact on blast damage and wall control was investigated as part of this contract Following the PIO methodology described earlier, three trial blasts using higher energy intensity were conducted for the harder M4/M4A ore and campaigned through the plant to assess the comminution circuit performance. These higher energy intensity blasts produced even finer Run-of-Mine (ROM) fragmentation and subsequently finer feed to the SAG mill. The SAG feed F80 (size that 80% of the feed material is smaller than) was reduced to around 50-60 mm compared to 100-120 mm previously, and the percentage of fines (-10mm material) was increased from 25% to 45%. Primary crusher power peaks were reduced significantly during these campaigns. In order to achieve optimal performance of downstream processes with the finer ROM, a number of changes and adjustments were made to the crusher, SAG and ball mill circuits. The resulting mill throughput averaged 4,100 tph for the three trial blasts and plant throughput above 4,500 tph was achieved for several hours during these trials.
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The optimization of the blast designs and subsequent downstream processes for each of the ore types ensured efficient utilization of the plantâ&#x20AC;&#x2122;s installed power. The additional blasting energy was more than compensated for by the considerable energy savings in the crushing and grinding processes, thus minimizing the specific energy consumption of the entire operation.
More output, less energy consumption At the beginning of the project, the operation achieved a throughput of 2600 tph with a specific energy consumption of 14 kWh/t. At the end of the project, throughput of 4500 tph was achieved and maintained with a specific energy of 10.5 kWh/t. This represents a significant increase in resource efficiency by reducing the total environmental impact of metal concentrate production with energy savings of 25% for Antamina.
CompaĂąĂa Minera Antamina is a polymetallic mining complex that produces copper and zinc concentrates as primary products and molybdenum and lead/bismuth/ silver concentrates as by-products. Antamina, situated in the central Peruvian Andes some 4,300 meters above sea level, represents one of the main complexes of the Peruvian mining industry.
Metso Global | www.metso.com
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NEWS & REPORTS BETEK GmbH & Co. KG
Betek CRUSHER TECHNOLOGY:
MAKING GRAVEL BY THE TON!
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sing tungsten carbide in open VSI crusher rotors has frequently been tested in the past. However, none of the machine manufacturers had any success with this, as crushing rock by the VSI method involves extreme forces. Now BETEK has taken on this challenge and the bold experiment worked: The test was run in a large German gravel quarry operating an open VSI crusher. Its standard centrifugal plates were made of cast steel. These were replaced 1:1 by newly developed tungsten carbide centrifugal plates from BETEK. The high-strength BETEK tungsten carbide soldering stood up to the extreme forces within the rotor. Centrifugal plates accelerate the rock at speeds of up to 70m/s. The stones then get broken into small pieces by smashing against the crusherâ&#x20AC;&#x2122;s impact plates. The good results in this test speak for themselves:
Uniform gravel by the ton: the BETEK tungsten carbide centrifugal plates performed great work in the quarry.
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NEWS & REPORTS Before: the impressive, uniform, high-quality end product.
The BETEK centrifugal plates lasted four times longer in use than the standard cast steel plates. With the machine running for the same time, crushing output was increased by 20%. Much less wear occurred on the impact plates opposite the centrifugal ones. In addition, less unbroken material had to be fed back again into the crusher. In the crushing results, too, the quarry experts noted clear improvements: in contrast to the steel ones, the tungsten carbide plates remained â&#x20AC;&#x2DC;in shapeâ&#x20AC;&#x2122; throughout the entire operating period and therefore permanently produced an even distribution of the rock and thus also particularly uniform gravel.
FOR MORE INFORMATION AND CONTACT: BETEK GmbH & Co. KG - Press contact Anne-Christine Jahnke, Marketing Sulgener Str. 21-23 D-78733 Aichhalden | Germany Tel.: +49 (0) 7422/ 565-183 Fax: +49 (0) 7422/ 565- 122 eMail: : a.jahnke@betek.de Internet: www.betek.de
After: the impressive, uniform, high-quality end product.
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NEWS & REPORTS BETEK GmbH & Co. KG
‘GROUND-BREAKING’ DEVELOPMENT:
BAUMA PREMIERE FOR OUR HSI ROTOR!
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n a fi eld test in a gravel quarry adjacent to the Black Sea we were able to convince even the last few sceptics of the benefits of our newly developed complete BETEK HSI crusher rotor. The new rotor, which was developed in conjunction with our partners Seytas, combines within it a whole package of interesting solutions: The newly developed HSI (horizontal shaft impact) crusher rotor from the two partners, SEYTAS and BETEK, was tested as it were ‘from top to toe’ in a gravel quarry near Trabzon in Turkey. This region had been specifically selected for this test of strength, as the sorts of rock found here are literally the hardest that the whole region has to offer in geological terms. For the plant and machinery used there, major problems of wear are the order of the day. River gravel consisting of quartz and basalt and with a base size of 40-150mm gets crushed in the quarry down to a target size of 15-25mm. As it soon emerged, this was precisely the right job for the new rotor unit from SEYTAS and BETEK, the special feature of which is a blow bar split into 7 segments fitted with tungsten carbide.
HSI crusher. Marked in red is the tungsten carbide, which is fitted wherever particularly high levels of wear occur. (Illustration.: A.-C. Jahnke, BETEK)
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NEWS & REPORTS The new HSI rotor has a sophisticated design that has many practical advantages. The test in Turkey confirmed that here too BETEK has found a good solution that helps the plant operator in many ways, removing a lot of everyday concerns.(CAD: BETEK)
The standard bars are in one piece and get completely replaced after they have worn down. The test was run over a period of 60 hours – the length of time it takes under the conditions described until – if not before – the standard bars have to be replaced.
These considerable advantages are a big plus for the SEYTAS BETEK HSI rotor, which were incidentally celebrated its premiere at BAUMA.
The test results With the help of the new rotor the crusher’s productivity was increased by 30%. The shape of the crushed material, a quality criterion on which extreme value is placed, was cubical and uniform, just as the customers like it. Changing the subdivided individual blow bar segments was quicker, simpler and safer than with the currently widely used standard bars. In terms of manpower, this means that just one worker is required to make the change rather than three. It was also possible to make the change just in the places that were actually worn – a huge potential saving for the machine operator. After being in use for the trial period of 60 hours our test rotor was still in good form and in true BETEK style could have made considerably more ‘progress’ without any downtime or changes.
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FOR MORE INFORMATION AND CONTACT: BETEK GmbH & Co. KG - Press contact Anne-Christine Jahnke, Marketing Sulgener Str. 21-23 D-78733 Aichhalden | Germany Tel.: +49 (0) 7422/ 565-183 Fax: +49 (0) 7422/ 565- 122 eMail: : a.jahnke@betek.de Internet: www.betek.de
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NEWS & REPORTS Maximus Crushing & Screening
Maximus Crushing & Screening : MXJ-1 Jaw Crusher debut at Bauma 2013
aximus Crushing & Screening – the premier manufacturer of materials handling equipment from Northern Ireland, has launched its first mobile M jaw crusher at the Bauma in Munich : 3D Steelwork Ltd was created in 2004 by Mr. Shane O‘Neill. The company initially started out as a structural steel company and soon became the premier structural steel company in Northern Ireland - engaged in the manufacture and supply of products and services used within the construction industry across Ireland and the UK. In 2008 the company diversified into the design, manufacture and supply of high quality screening and conveying machinery for use in the quarry, mining, construction and materials handling industries. This diversification came under the newest and freshest brand name on the market - Maximus Crushing & Screening. Maximus Crushing & Screening has already established a reputation for producing high quality, reliable, heavy duty vibrating screeners and conveying systems and has brought to market 7 new tracked mobile screening machines and a range of static and mobile conveyors and screening units. In the last 3 years, more than 200 screening plants were sold in more than 20 countries all over the world and are successfully in operation in a variety of climates and harsh working conditions.
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Our ever expanding product range has led to an exciting growth period for the company - currently with 75 employees and aiming to increase our workforce even more over the coming years. This new product range was further enhanced by the launch of 3 new products - the T8048 track conveyor, the Maximus 620 scalping unit and more importantly - the MXJ-1 Jaw Crusher which had its world premiere at the Bauma Show.
MXJ-1 Jaw Crusher Now the company has taken major steps in its evolution and has developed the first crushing unit – the MXJ-1 mobile jaw crusher – which will be launched at the Bauma in Munich to the global audience. The mobile crusher comes with a fresh, modern design and is equipped with a user friendly control system to maximise the machine production capabilities.
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NEWS & REPORTS The MXJ-1 is equipped with a huge feedhopper with 10 m3 capacity, a grizzly pre-screening grid and a large 1200 mm main conveyor belt. The Jaw crusher has an inlet opening of 1150 x 750 mm (45 ¼“ x 29 ½“) and is equipped with hydraulic wedge adjustment. The powerful C9 CATengine gives enough strength to perform in the hardest conditions. The MXJ-1 has been designed with easy access for maintenance and service in mind. The electrical system is modern and user friendly, plant set-up is fast and flexible, and with a transport weight of just 45 tons.
Heavy duty mobile scalper 620 The Maximus 620 is a heavy duty, high capacity mobile scalper designed for large scale operators and capable of screening a wide variety of material in the harshest conditions. It is designed to cope with the heaviest applications and can be used in construction and demolition waste, primary crusher circuits, iron ore, aggregates, coal, recycling, heavy rock and topsoil. The Maximus 620 is equipped with a 225 Hp (168 kW) CAT C6.6 Diesel engine with shut down protection, a heavy duty hopper with 8.7 m3 (11.7 yd3) capacity and a high energy 2 Bearing 20 x 6 screenbox which rises at the lower end for bottom deck access for maintenance or service. The tail conveyor is fitted with a 1.6 m (63“) wide chevron belt and 2 integrated side conveyors. All belts can be folded hydraulically for transport. The Maximus 620 is an extremely versatile screener with many options available and is set-up shortly after arriving at the jobsite.
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Maximus T80-48 Track Conveyor The MAX T80-48 is the largest conveyor in our range and is designed for ease of mobility on site. It is manufactured with a highly robust chassis for optimal strength in difficult working conditions. The T-Series of conveyors are designed to optimise stockpile capacities and minimise on-site material handling costs. The hydraulic folding head section in the MAX T80-48 allows for fast efficient road transportation and the machine has a typical set-up time off less than 10 minutes. The T80-48 has a 48“ (1220mm) wide belt and is 80‘ (25m) in length. It comes with a powerful Cat C2.2 engine and has hydraulically adjustable feed boot and head section heights. The T80-48 has a number of options available, including radio control tracks, electric drive, dust suppression , etc.
FOR MORE INFORMATION AND CONTACT: Maximus Crushing & Screening 2A Washingbay Road, Coalisland Co Tyrone, Northern Ireland, BT714ND Office: +44 (0) 288 744 88 73 eMail: info@maximusscreening.com Internet: www. maximusscreening.com Press contact: Barry O’Neill eMail: barry@maximusscreening.com
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NEWS & REPORTS JOEST GmbH + Co. KG
JOEST GmbH + Co. KG: BAUMA und POWTECH 2013 successfully completed BAUMA und POWTECH 2013 successfully completed In April 2013 JOEST had been at the BAUMA in Munich and at the POWTECH in Nuremberg. For JOEST, the appearance on the exhibitions was a complete success. We appreciate the excellent attendance and strong interest in our booth and our products. The ehxibitions were a great platform for us. We presented our unique new development - OSCILLA - a broad audience.
FOR MORE INFORMATION AND CONTACT: JOEST GmbH + Co. KG Gewerbestr. 28-32 48249 Dülmen Tel.: +49 (0) 2590 98-0 Fax: +49 (0) 2590 98-101 eMail: info@joest.com Press contact: Internet: www.jöst.com Vera Böckermann Assistant of sales management Tel.: +49 (0) 2590 98-169 eMail: vboeckermann@joest.com
The response was fantastic, and we are proud of the strong positive feedback. JOEST® – the expert for bulk solids We are a medium sized, owner-managed company and international leader in the field of vibration technology. Our core competence is the design and manufacture of vibrating screens, vibrating drives, and process engineering complete solutions for processing of bulk materials. Philosophy: We treat employees, customers, partners, and competitors fairly and honestly and communicate openly and effectively. We satisfy our customers with excellent quality, reliability, flexibility and with a deep understanding of their business.
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NEWS & REPORTS JOEST GmbH + Co. KG
JOEST GmbH + Co. KG: Start-up of Europe´s biggest vibrating machine
Start-up of Europe´s biggest vibrating machine Over Easter JOEST delivered and mounted Europe’s biggest vibrating machine – a casting cooler with a capacity of 55 t/h automotive castings for one of the biggest customer foundries in Germany. Thanks to good Project Management production could start-up on time even though the time schedule was very tight. Machine-dynamic the casting cooler is carried out as active mass-compensated resonance machine with single vibration absorber. Thermo-dynamic the cooling function is based on a convective casting/air countercurrent heat exchange. The effective length of the machine is 37000 mm and the outside width 3800 mm. The net weight of the casting cooler is 72.000 kg. For the transport and easier installation the cooler had to be split into several sections.
With more than 90 years experience is JOEST one of the worldwide leading companies in the field of vibration technology and bulk handling with subsidiaries and agencies all over the world.
FOR MORE INFORMATION AND CONTACT: JOEST GmbH + Co. KG Gewerbestr. 28-32 48249 Dülmen Tel.: +49 (0) 2590 98-0 Fax: +49 (0) 2590 98-101 eMail: info@joest.com Press contact: Internet: www.jöst.com Vera Böckermann Assistant of sales management Tel.: +49 (0) 2590 98-169 eMail: vboeckermann@joest.com
JOEST® – the expert for bulk solids We are a medium sized, owner-managed company and international leader in the field of vibration technology. Our core competence is the design and manufacture of vibrating screens, vibrating drives, and process engineering complete solutions for processing of bulk materials. Philosophy: We treat employees, customers, partners, and competitors fairly and honestly and communicate openly and effectively. We satisfy our customers with excellent quality, reliability, flexibility and with a deep understanding of their business.
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NEWS & REPORTS
JOEST GmbH + Co. KG: delivers double deck screen to polar circle
JOEST GmbH + Co. KG
JOEST delivers double deck screen to polar circle Once again JOEST could prove their longterm experience and competence with vibratory screens. In December 2012 JOEST installed a double deck screen and a conveying feeder for a Norwegian customer north of the polar circle. The total scope of supply contains one double deck screen with a width of 3 m and a length of approx. 10 m, resulting in a screening surface of nearly 28 m² per deck. A counter frame, cover and different material chutes were also included. The machine is driven by two big JOEST exciters, JR 1018 with 75 kW three-phase motor. JOEST also delivered a vibratory feeder with a width of more than 2,5 m and a length of nearly 2,5 m, with counter frame, chutes and steel construction.
With a total weight of approx. 80 t, the transport to the site required a special oversize transport with 6 trucks. The JOEST screen will be used for screening of iron ore pellets in Narvik – Norway.
FOR MORE INFORMATION AND CONTACT: JOEST GmbH + Co. KG Gewerbestr. 28-32 48249 Dülmen Tel.: +49 (0) 2590 98-0 Fax: +49 (0) 2590 98-101 eMail: info@joest.com Press contact: Internet: www.jöst.com Vera Böckermann Assistant of sales management Tel.: +49 (0) 2590 98-169 eMail: vboeckermann@joest.com
JOEST® – the expert for bulk solids We are a medium sized, owner-managed company and international leader in the field of vibration technology. Our core competence is the design and manufacture of vibrating screens, vibrating drives, and process engineering complete solutions for processing of bulk materials. Philosophy: We treat employees, customers, partners, and competitors fairly and honestly and communicate openly and effectively. We satisfy our customers with excellent quality, reliability, flexibility and with a deep understanding of their business.
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NEWS & REPORTS Kleemann GmbH
Global innovation in the Contractor market:
New mobile jaw crusher generation from Kleemann!
The new mobile jaw crushers from Kleemann: Mobicat MC 110 EVO
At this yearâ&#x20AC;&#x2DC;s bauma Kleemann had shown for the first time its new jaw crushers Mobicat MC 110 Z and MC 110 R, which further expand the successful EVO Contractor Line of Kleemann. Also here EVO represents a redevelopment of the entire plants, real progress in terms of power and efficiency.
Complete new designs The plants of the new Mobicat EVO series have been redesigned from scratch, thus allowing the combination of new features such as the hopper walls integrated in the chassis or a fully hydraulic crushing gap adjustment with tried-and-tested concepts like the independent doubledecker pre screen, making the plants even more diverse and efficient.
Crusher direct drive, electric auxiliary drives Similar to the mobile impact crushers in the Mobirex EVO series, drive variants with direct drive crushers and electric drives for the vibrating conveyors, belts and the pre screen, are now used for the mobile jaw crushers. This means extremely efficient operation and allows optimal loading of the crusher. The so-called CFS (Continuous Feed System) controls an even more equal loading of the crushing area, in which the conveying frequencies of the feeder trough
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and the pre screen are adapted independently of each other to the level of the crusher and thus help increase the performance significantly.
New crushing unit with hoisted crusher jaw The new crusher impresses with its hoisted articulated crusher jaw, which on the one hand prevents blocking of coarse material and on the other hand takes all fastening elements of the crusher jaw from the wear area. In addition, the transfer from the pre screen or the feeder trough is designed so that the material can simply tilt into the crushing jaw and convey an even material flow. With this property and other features Kleemann achieves outputs of up to 300 tons per hour.
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Wirtgen Gmbh: Wirtgen GmbH
New generation of Wirtgen point-attack cutting tools and HT22 quick-change toolholder system underscore Wirtgen‘s unique cutting technology
A perfect match: the HT22 quick-change toolholder system and Generation X pointattack cutting tools interact optimally to yield an exceedingly precise milled result and a road pavement with maximum evenness.
Cutting technology with milling drum, toolholder and point-attack cutting tools is a core competence of Wirtgen. Perfect interaction between these components is essential to maximize the performance of every cold milling machine. At bauma 2013, Wirtgen was presenting two revolutionary new developments – namely its Generation X point-attack cutting tools and the HT22 quick-change toolholder system – boosting the unique performance and cost-efficiency of Wirtgen cold milling machines to a new level.
Generation X point-attack cutting tools: higher output, lower costs Generation X is the name of the new series of pointattack cutting tools developed by Wirtgen in close collaboration with its long-standing systems partner Betek in Aichhalden. The result is a robust cutting tool with greatly enhanced wear resistance and enormous cutting power for high milling output. The innovative geometry of their carbide tips, for example, extends the service life of the new cutting tools by up to 20% in relation to conventional cutting tools, with constant high milling output. Their wear resistance has simultaneously been improved by optimizing the composition of the carbide material. „Finding the right mixture of coarse and fine tungsten carbide is important in determining the wear resistance as well as the breaking strength of the carbide tip,“ explains Thomas Lehnert, responsible for cutting tool development at Wirtgen.
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The massive wearing plate now includes a more prominent centring cone. This ensures not only that the cutting tool is precisely supported in the toolholder, but also that it is essentially self-centring. The transverse forces encountered in the cutting process are more effectively discharged, thus minimizing the risk of the cutting tool‘s shank breaking. Longitudinal wear in the toolholder is additionally reduced as the tool is optimally guided in the toolholder.
HT22 quick-change toolholder system: longer life, shorter downtimes Development of the new HT22 quick-change toolholder system has made it possible to more than double the maximum useful life of the toolholder upper part and significantly increase the service life of the milling drum. Maximum longitudinal wear of the upper part has doubled
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NEWS & REPORTS in relation to that of the conventional version. Service intervals for checking screw tension have also been extended from 250 hours in the past to 500 hours now, due to the system‘s generally more robust construction. The reliable yet simple screw connection has already proved its value during the new HT22 quick-change toolholder system‘s prototype phase of more than two years.
Robust, durable Wirtgen cutting technology components cut operating costs Wirtgen‘s continuous further development of cutting technology is always based on the aim of boosting performance and cost-efficiency in order to offer customers a reliable solution. The new Generation X point-attack cutting tools will consequently be available when bauma opens. Cold milling machines and their milling drums will be equipped with the new HT22 quickchange toolholder system starting in August, when it can also be retrofitted in customers‘ machines. „With these two new developments, our engineers have once again delivered practical innovations combining maximum milling output with efficient operating costs,“ says Bernd Holl, product manager for cold milling machines at Wirtgen. This yields twofold benefits for the customer who is then optimally prepared for future milling jobs.
The newly developed HT22 quick-change toolholder system: increasing the wearing length significantly extends the service life of the toolholders.
FOR MORE INFORMATION AND CONTACT:
Wirtgen is introducing its new Generation X point-attack cutting tools in time for bauma, thus optimizing the performance and cost-efficiency of the Wirtgen cold milling machines.
Wirtgen GmbH - Press and Public Relations Michaela Adams, Mario Linnemann Reinhard-Wirtgen-Straße 2 53578 Windhagen | Germany Tel.: +49 (0)26 45 - 1 31-0 Fax: +49 (0)26 45 - 1 31 499 eMail: presse@wirtgen.com Internet: www.wirtgen.com
Wirtgen - a strong brand of the Wirtgen Group Wirtgen GmbH is a member company of the Wirtgen Group, an internationally active group of companies in the construction equipment industry. The group comprises the four renowned brands Wirtgen, Vögele, Hamm and Kleemann, all headquartered in Germany, as well as local production facilities in Brazil, China and India.
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Wirtgen rounds out Wirtgen GmbH
new generation of cold recyclers and soil stabilizers
WR240: Outstanding! Wirtgen won the iF product design award in gold in the category “Special Vehicles / Construction / Agriculture” for the WR 240, one of the most coveted international design prizes. The award evaluates aspects such as degree of innovation, environmental impact, functionality, ergonomics and product safety.
Maximum quality every time – the WR 240 already delivered this level of performance when it was introduced to the market in summer 2012 as the first representative of the new-generation cold recyclers and soil stabilizers. With the two, new WR 200 and WR 250 models, Wirtgen rounded out this product segment at this year bauma 2013.
New standards in cold recycling and soil stabilization
A small compact machine (WR 200) meets a powerhouse (WR 250)
With the world’s largest line of recyclers and soil stabilizers, Wirtgen has the right solution for every application. For example, the WR 240 is considered to be an all-rounder for the heavy-duty stabilization of large areas of non-cohesive soil, and for the conservative cold recycling of damaged asphalt layers.
Wirtgen is presenting the WR 200 at bauma 2013, a smaller version of the WR 240. It boasts nearly identical features for both cold recycling and soil stabilization. It shows off all its capabilities in these applications, specifically its maneuverability on small, tight construction sites. Furthermore, it requires no special transport permits and is therefore ideal for one-day jobs.
A variety of new features make it a pioneer in terms of performance and cost-efficiency, and it has impressively demonstrated both of these in practical use in recent months, as the exclusively positive feedback from customers confirms. Despite its higher productivity, the WR 240 consumes significantly less fuel thanks to state-ofthe-art engine management, and therefore considerably reduces costs for contractors. What is more, their machine operators praise the large, modern cabin, the all-around view it affords, the machine‘s improved manoeuvrability, its optimized ergonomic design and its intuitive operation.
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The WR 250 is the most heavy-duty machine of the new WR generation. This powerhouse is designed for stabilizing heavy, swampy soils and comes into its own on recycling and pulverization jobs, where it turns roadways up to 25 cm thick into homogenous granulate. What is new is the option of also operating the milling drum from the cabin, making it possible to flexibly activate a number of milling drum speeds.
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NEWS & REPORTS The milling drum design tailored to the WR 250’s high output helps to achieve outstanding mix quality at a high feed rate.
iF product design award in gold for the Wirtgen WR 240 In addition to their innovative features, all three models lastly win out with their ultra-modern design. The WR 240 even won the iF product design award in 2013 in gold, one of the world’s foremost design prices.
FOR MORE INFORMATION AND CONTACT: Wirtgen GmbH - Press and Public Relations Michaela Adams, Mario Linnemann Reinhard-Wirtgen-Straße 2 53578 Windhagen | Germany Tel.: +49 (0)26 45 - 1 31-0 Fax: +49 (0)26 45 - 1 31 499 eMail: presse@wirtgen.com Internet: www.wirtgen.com
Wirtgen - a strong brand of the Wirtgen Group Wirtgen GmbH is a member company of the Wirtgen Group, an internationally active group of companies in the construction equipment industry. The group comprises the four renowned brands Wirtgen, Vögele, Hamm and Kleemann, all headquartered in Germany, as well as local production facilities in Brazil, China and India.
WR250: Cold recycling and soil stabilization made easy. The new WR generation offers even greater output, high cost-efficiency and easy handling.
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Wirtgen Pick Inspection (WPI):
Wirtgen GmbH
The smart surface miner thinks for itself
Thanks to WPI, service technicians can identify worn picks quickly and replace them in a few swift moves. This saves companies both time and money.
With the launch of WPI, Wirtgen is introducing a new system which measures the wear of surface miner cutting tools. WPI – Wirtgen Pick Inspection – principally comprises eight very rapid measuring sensors which are integrated in the cutting drum compartment of the surface miner. These sensors measure the degree of wear of the picks. Taking just one minute to complete, the measuring process can easily be carried out while changing trucks, thus avoiding downtimes.
App for service teams slashes toolchanging times WPI is very simple to operate: the entire measurement proceeds fully automatically at the push of a button. A separate mobile end device, which forms part of the cutting drum, marks the worn pick in colour on its display. The result of the measurement is displayed clearly, making life very much easier for machine operators and service technicians, who can plan the necessary service intervals optimally – both in terms of personnel requirements and spare parts stocks – based on the wear information for individual machines. The system also ensures that the cutting tools can be used for the maximum length of time. These optimized service and production processes will offer vast material benefits to mining companies which use entire fleets of surface miners in 24/7 operation. WPI gives the machine operator a fast and simple overview of the degree of wear of the picks – without causing downtimes.
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NEWS & REPORTS Wirtgen GmbH
Top Precision Completely without Stringlines: Wirtgen Slipform
Paver SP 25i with AutoPilot Field Rover
The AutoPilot steered the SP 25i from Wirtgen in the construction of the three meter wide dyke path by Böhling Bauunternehmung GmbH. The height was controlled by a laser transmitter with the appropriate receiver on the paver.
In the past, stringlines always had to be set up expensively and time-consumingly for the construction of concrete sections. These caused obstructions during installation and had to be removed again at the end of the project. Those days are now over because the AutoPilot from Wirtgen with Field Rover heralds a new era. The satellite-aided navigation system controls the steering and cross slope of the slipform paver fully automatically – without the effort of creating a digital terrain model.
Wirtgen AutoPilot Field Rover receives bauma Innovation Award 2013 The AutoPilot Field Rover has been on the market since the beginning of the year and has now won the bauma Innovation Award 2013. Wirtgen offers this new technology for the SP 15 and SP 15i as well as the SP 25 and SP 25i pavers. It can also be retrofitted to these machines. „These slipform pavers are excellently suited for the offset installation of monolithic sections or the constructions of narrow road surfaces. And these are ideal jobs for the AutoPilot,“ Martin Datzert, sales and application specialist for slipform pavers at Wirtgen Windhagen Vertriebs- und Service GmbH explains. He knows the possibilities of the system because, together with the Wirtgen GmbH developers team, he supervised construction sites at which the AutoPilot and Field Rover were in operation immediately before its market launch.
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The following two examples show that installation without stringlines works even under different basic conditions. These range from a three meter wide road surface for a cycle path to the concrete protection wall on a freeway..
3,500 meters of perfection without a stringline BIn February 2013, VSB infra GmbH & Co. KG, Dortmund, became the first German company to buy an SP 25i with AutoPilot. Managing Director Kay Petersen and his team have thoroughly tested the new technology in advance, in the construction of a 3.5 kilometer long concrete protection wall on the A7 freeway near Bockenem among other projects. The 90 centimeter high wall with step profile was built parallel to the new road surface. VSB infra completely dispended with the use of stringlines.
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NEWS & REPORTS No stringline obstructed the construction of this concrete protection wall. The VSB infra construction team enjoyed the freedom of movement just as much as the concrete mixer drivers – they can maneuver in front of the paver much better without a stringline.
Instead, construction manager Thorsten Kräutner recorded measuring points at intervals of 20 meters with the Field Rover a few days before beginning construction. „It‘s quite simple: As is normal with surveying, the stretch along which the construction is to be laid is plotted with the survey pole. Individual measuring points are defined. The software in the Field Rover computes the course of the reference line from these – the virtual stringline so to speak. In this way the user can quite easily create his own digital terrain model with the Field Rover,“ slipform paver specialist Datzert, who is the contact person for concrete pavers in Germany, explains. „The recorded data can be viewed on the Field Rover display and re-edited if necessary,“ the developer and survey engineer Matthias Fritz from Wirtgen GmbH adds. „When everything is perfect, you transfer the data from the Field Rover to the slipform paver by USB stick.“ When starting work, the Wirtgen slipform paver moves automatically to the defined starting point and works from there along the reference line with millimeter accuracy.
Enormous time saving „The big advantage of this method is that there is no stringline to obstruct the team around the paver. The concrete mixers also have more room to maneuver. This makes the work much easier and quicker,“ says Dipl.-Ing. Petersen as he recalls his first experiences with the new system. But for him, other aspects are also relevant: „The time for setting the lines is saved. This is noticeable above all for radii, for example at roundabouts. The points are recorded with the Field Rover in no time at all – not like before where the surveying and setting of the lines took just as much time as the construction.“ The data recording is particularly fast when the concrete profile is to be built on existing road sides. The user can then record the data on site and transfer them to the paver within minutes.
Construction of a cycle path in Bosse in the Lüneburg Heath: Bends with tight radii are also possible without a stringline with the Wirtgen AutoPilot.
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The machine operator can see the status of the AutoPilot on a separate display the whole time.
Goodbye to trip hazards Böhling Bauunternehmen GmbH in Friedeburg in Northern Germany used the system in Bosse at the southern perimeter of the Lüneburg Heath. Here, a three meter wide dyke path was constructed along the river Aller with various slopes, bends with slight elevations and long straights. One day before beginning construction, Wirtgen specialist Matthias Fritz together with Franck Alberts, foreman at Böhling, went along the track and recorded about 60 measuring points along the two kilometer long stretch with the Field Rover. „A certain preparation time is necessary even with the Field Rover but it is much quicker and less personnel-intensive than all the other available methods,“ Martin Datzert knows.
As soon as the data are transferred to the paver and the SP 25i is installing the concrete profile, it constantly compares the current position with the nominal data. At a reference station set up at the side of the construction site the paver receives a DGPS signal which gives the position precisely with an accuracy of one centimeter. The paver control system generates the steering signals from the differences between the nominal and actual data. The driver no longer has to intervene. On this principle the AutoPilot also took over the control of steering and cross slope on the construction site in Bosse – even in the bends. Machine operator Torsten Fabricius always had the position and the current parameters in view on the display but was able to concentrate totally on the coordination with the concrete mixer and his colleagues on the ground. They, on the other hand, appreciated being able to work without stringlines as did the drivers of the concrete mixers.
Sensors for height adjustment While the AutoPilot steers, the height adjustment is controlled by an additional sensor. This may be an ultrasound sensor or a ski sensor, a laser receiver or a total station depending on the nature of the ground and the local topography. A laser sensor was used on the dyke path construction site. A different story on the freeway construction site: VSB infra scanned the new road surface with an ultrasound sensor – an ideal reference.
The AutoPilot Field Rover won the bauma Innovation Award in the „Component“ category. The jury praised the Field Rover as a trailblazing development for road construction.
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NEWS & REPORTS Convincing new paver generation When testing the AutoPilot, VSB infra GmbH & Co. KG and Böhling Bauunternehmen GmbH were also able to judge the new SP 25i. Managing Director Egon Böhling especially praised the new, very accurate steering and the many sophisticated details. Managing Director Kay Petersen was thrilled with the convenient operation of the slipform paver, its high transport and maneuvering speed and the economical engine concept. These were just some of his reasons for deciding to buy a machine immediately after the tests. VSB infra is therefore the first company in Germany to use the AutoPilot and, as Petersen says, „the system convinced me one hundred percent.“ With the purchase of the machine, Wirtgen trainers provided AutoPilot training for the entire construction team of VSB infra Kay Petersen knows why: „It is not just the construction managers, who will record the data with the Field Rover later, who need to be familiar with the system. The foremen and machine operators also have to know how the AutoPilot works and what it can do. When that is the case, we can exploit all the economical advantages and produce optimum quality.“
FOR MORE INFORMATION AND CONTACT: Wirtgen GmbH - Press and Public Relations Michaela Adams, Mario Linnemann Reinhard-Wirtgen-Straße 2 53578 Windhagen | Germany Tel.: +49 (0)26 45 - 1 31-0 Fax: +49 (0)26 45 - 1 31 499 eMail: presse@wirtgen.com Internet: www.wirtgen.com
Wirtgen - a strong brand of the Wirtgen Group Wirtgen GmbH is a member company of the Wirtgen Group, an internationally active group of companies in the construction equipment industry. The group comprises the four renowned brands Wirtgen, Vögele, Hamm and Kleemann, all headquartered in Germany, as well as local production facilities in Brazil, China and India.
The AutoPilot steered the SP 25i from Wirtgen in the construction of the three meter wide dyke path by Böhling Bauunternehmung GmbH. The height was controlled by a laser transmitter with the appropriate receiver on the paver.
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NEWS & REPORTS Case Construction Equipment Inc.
Case Construction Equipment : Case Machinery
Supports Quarry Company Growth
Quarry operator and civil engineering contractor GD Harries & Sons is expanding its business with the addition of four machines from local Case Construction Equipment dealer Riverlea. The company, from Narberth in West Wales, has taken two Case CX350C crawler excavators, a 1021F wheeled loader and a 821F for use in its seven quarry sites throughout the region.
Geographic And Business Expansion In the past 18 months Harries has acquired four granite and two limestone quarries. The company also runs three concrete production plants and three aggregate coating facilities, and has expanded its interests into road surfacing and other civil engineering contracting operations alongside the quarry works.
The four Case machines have been purchased to replace existing machinery as part of an overall plan to upgrade the fleet. The 35-tonne CX350C excavators are now the largest machines on the fleet and, along with the two wheeled loaders, will contribute to an increase in production levels within the quarry operations. GD Harries runs a large fleet of equipment with many Case machines and has established a very successful relationship with local dealer Riverlea over many years of working together. “Excellent local dealers and right on our doorstep,” says Harries business manager Janet Phillips. “We did price other equipment but Riverlea was able to put together the best deal for us in terms of price and quality – also Paul Austin pulled out all the stops in terms of customer service and this mix left us with no alternative but to stay with Case machinery.” The company, which has more than 235 employees, runs its own service engineer division and haulage fleet. However, it does
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rely on the dealer for rapid supply of parts to ensure the machines provide maximum availability. “”We do have our own maintenance staff to keep the machines running,” says Ms Phillips. “But Riverlea has always been there to look after us when we need them.” The machines have already found favour with Harries’ operators, who she says: “Have taken to them like ducks to water.” Supplied in standard specification, the equipment is already delivering a boost in productivity for the company. With a continued growth in demand for aggregate throughout the region, Ms Phillips says the company will be looking for additional machinery before long. Riverlea has been a Case Construction Equipment dealer throughout Wales for more than 20 years and the company has built many strong working relationships with customers over that time. Press contact: Lynn Campbell TLC PR for ALARCON & HARRIS Tel: +44 1704 566354 eMail: lynn@tlcpr.co.uk
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“GD Harries is a long established customer and we have had a really good relationship with them for many years,” says construction sales manager Paul Austin. “The company runs a lot of Case equipment and we have always worked to support them wherever possible.”
Case Construction Equipment Inc. sells and supports a full line of construction equipment around the world, including the No. 1 loader/backhoes, articulated trucks, crawler and wheeled excavators (including compact), telescopic handlers, motor graders, wheel loaders (including compact), vibratory compaction rollers, crawler dozers, skid steers, compact track loaders, tractor loaders and rough-terrain forklifts. Through Case dealers, customers have access to a true professional partner - with world-class equipment and aftermarket support, industry-leading warranties and flexible financing. More information is available at www.casece.com. Case is a division of CNH Global N.V., whose stock is listed at the New York Stock Exchange (NYSE:CNH), which is a majority-owned subsidiary of Fiat Industrial S.p.A. (FI.MI). More information about CNH can be found online at www.cnh.com .
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NEWS & REPORTS Case Construction Equipment Inc.
Case Construction Equipment : SiteWatch
Puts Fleet Managers In The Driving Seat
Case SiteWatch is an essential fleet management tool that lets the customer take complete control of their machinery, their fleet maintenance and their operating costs. With real-time diagnostic and telematic capabilities, SiteWatch puts the fleet manager in the operatorâ&#x20AC;&#x2122;s seat of every machine that the company runs, reducing downtime, cutting fuel consumption and saving money. By accurately measuring operating performance, customers can increase productivity, boost utilization and keep on top of fleet maintenance issues. With programmed maintenance plans, the operator can even leave the service and maintenance requirement to their Case dealer, secure in the knowledge that their machinery is receiving the most cost effective back-up service available.
The data can be monitored by the customer and directly by their Case dealer on any web-enabled computer or tablet, ensuring that service and repair issues can be handled efficiently and quickly. By having regular operating data, customers and dealers can preplan service schedules, ordering spare parts and filters in advance and planning maintenance downtime to meet the needs of the site.
Regular Data Transfer
Flexible Reporting
The Sitewatch Control Module constantly gathers information from the machineâ&#x20AC;&#x2122;s control systems, including machine location, productivity, fuel efficiency, maintenance requirements and operating health parameters. This data is automatically transmitted through the telematic link to the Case user web portal.
Case SiteWatch provides critical operating information concerning the entire fleet of equipment. Customers can access this data through the web portal and receive regular tailored reports relating to the fleet. This can include machine location maps, fuel use reports for individual machines that can be used to improve operator efficiency, machine activity reports that help to increase utilisation and CAN-Bus reports that provide analysis of detailed operating parameters.
The Advanced system, supplied with dozers, wheeled loaders, crawler and wheeled excavators, sends a data report every 10 minutes, the highest transmission frequency on the market for real time reporting. A Basic subscription plan for tractor backhoe loaders, compact tracked loaders, skid steer loaders and midi excavators reports every two hours. Both subscription packages have a three-year duration, with extensions available through the dealer spare parts channel.
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By analysing this information fleet managers and owners can best assess how their equipment is being used, allowing them to move machines for more productive operation, cut idle times and excess fuel use
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and boost utilisation of the entire fleet. It can also flag up a requirement for additional operator training or the need for monitoring of fuel use on a specific site.
Enhanced Machine Security Along with operating efficiency, SiteWatch provides customers with accurate positioning data, delivering geofencing and curfew options that can prevent machinery being used without authorisation. As well as providing a theft detection solution, this is particularly useful for rental companies, as they can monitor if machines continue to be used after the hire period has finished, charging the customer accordingly. The machine owner can be automatically notified if the machine is moved without authorization, helping to prevent theft on site and in some cases lowering insurance costs for the customer.
Additional Machine Protection
ranges. There is also a Universal SiteWatch kit that can be used with any brand of machine. It allows customers to run a mixed fleet on a single fleet management system.
Case Construction Equipment Inc. sells and supports a full line of construction equipment around the world, including the No. 1 loader/backhoes, articulated trucks, crawler and wheeled excavators (including compact), telescopic handlers, motor graders, wheel loaders (including compact), vibratory compaction rollers, crawler dozers, skid steers, compact track loaders, tractor loaders and rough-terrain forklifts. Through Case dealers, customers have access to a true professional partner - with world-class equipment and aftermarket support, industry-leading warranties and flexible financing. More information is available at www.casece.com. Case is a division of CNH Global N.V., whose stock is listed at the New York Stock Exchange (NYSE:CNH), which is a majority-owned subsidiary of Fiat Industrial S.p.A. (FI.MI). More information about CNH can be found online at www.cnh.com .
Case Protection Plans are available on the full range of Case machinery. There are three coverage options: Powertrain, Powertrain plus Hydraulics, and Premier, with cover available for up to five years/8,000 hours. In addition customers can have a Programmed Maintenance Plan through their Case dealer. Under these agreements the customer knows exactly what the machine operating costs will be. SiteWatch, the Case protection plan and a maintenance program, allow the dealer to respond rapidly to potential issues on site and to plan coordinated regular maintenance with the customer. The data also allows the dealer to closely monitor individual machines, with alerts for diagnostic concerns and troubleshooting issues.
Available From The Factory Case SiteWatch will be available as an option on some models directly from the factory. Alternatively customers can order SiteWatch as a dealer-installed accessory, with specific kits available for various model
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Press contact: Lynn Campbell TLC PR for ALARCON & HARRIS Tel: +44 1704 566354 eMail: lynn@tlcpr.co.uk
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Continuous training for the Mining industry: Advanced Mining Academy More information about the
“ADVANCED MINING ACADEMY“ you will find here:
www.advanced-mining.com/academy
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NEWS & REPORTS BAUER Maschinen GmbH
BG ValueLine – The expert in Kelly drilling
BG ValueLine The requirements for an „optimum“ drilling rig are extremely varied – and frequently even contradictory in nature. In many markets, the production of boreholes by the uncased Kelly drilling technique with extensive drilling depths or large drilling diameters is the dominant process. For other customers the availability of different drilling systems without the need to change the base machine is the decisive selection criterion. With the diversification of its rotary drilling rig series into the BG ValueLine and the BG PremiumLine range, BAUER Maschinen GmbH has introduced two distinct product lines to be able to provide a more targeted response than ever before to the many different market-specific requirements. The BG ValueLine drilling rigs are optimized for Kelly drilling. They can be employed for Kelly drilling projects such as drilling cased boreholes, drilling uncased deep boreholes that are stabilized by drilling fluid, and installing casings by the rotary drive or optionally by a hydraulic oscillator. With the different machine sizes, Bauer covers the full range of possible Kelly projects. Engineering and design of the entire product range offer state-of-the-art technology and facilitate highest performance across the full range of Kelly applications. In addition, our engineers have created an extremely maintenance-friendly design together with products that are easy and cost-effective to operate. The main highlights for the ValueLine product range are illustrated below: • • • • •
Simplified upper Kelly guidance to reduce the wear of the Kelly and to reduce the overall weight of the machine Patented crowd system for easy mast assembly Rotary drive – simple gear with high torque and integrated Kelly damping system Patented inclination supervision system for increased operating safety Mast head for easy transportation and facilitated handling
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• • • • •
Long, self-erecting mast for high drilling depths and easy handling Main winch with specially grooved winch drum to reduce wear on the winch rope Access ladder for working at higher safety Rear view camera for increased safety Cabin with excellent visibility including screen panel
To summarize, the BG ValueLine is an expert in Kelly drilling. By omitting unnecessary attachments required solely for other processes, the Kelly drilling technique becomes even more cost-effective and produces extraordinary drilling performance data at a low operating weight. In addition to the optimized Kelly drilling performance, several new features increase the functionality of the machine whilst maintaining the increasing quality standards of Bauer rotary drilling rigs. All this leads us to the attributes that both products ranges of the Bauer drilling rigs have in common. The BG ValueLine and the BG PremiumLine share a number of fundamental design principles which are given highest priority by BAUER Maschinen GmbH. They include, first and foremost, quality, cost-effectiveness and excellent performance in any specific range of application. Added to these are key design characteristics, such as a high level of safety standards, a high degree of serviceability and environmental sustainability and a long service life. Even a perfect rig is nothing without the right support: the Bauer package makes the difference. In addition to drilling rigs specially designed to meet customer requirements and tools proven in all soil conditions, our experts are always happy to assist. Be that in the selection of the most
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NEWS & REPORTS appropriate drilling technique, the provision of professional advice in the application of the selected technique or the induction training of your operators or mechanics. Thanks to our worldwide service network, our after-sales service
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is also highly flexible and offers a unique combination of equipment knowledge and application competency. When you decide to purchase a Bauer rig youâ&#x20AC;&#x2122;ll receive the whole package â&#x20AC;&#x201C; everything from a single source!
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NEWS & REPORTS BAUER Maschinen GmbH
Bauer deep drilling rigs – groundbreaking technology Bauer deep drilling rigs – groundbreaking technology The question of energy supply is a key issue for the global economy. Despite all the efforts to develop alternative and renewable energy forms, fossil fuel resources will remain the focus of interest for a long time to come. This is underscored by the fact that many extraction techniques have been advanced in recent times, and new possibilities are opening up. BAUER Maschinen GmbH has for a number of years been designing and building deep drilling rigs usable for a variety of different processes. The first prototype – later followed by a range of rigs in different sizes – was the TBA 300, a deep drilling rig capable of drilling down to a depths of around 5,000 metres. The figure in the rig designation indicates the load-carrying capacity in American short tons. In order to demonstrate the rig‘s functional safety to the highly demanding customers in this sector, an extensive programme of testing was conducted on a 1,500 metre deep bore.
where it may be needed. RB-T 90 drilling rigs offer a maximum load-carrying capacity of 90 tonnes. The maximum small-diameter drilling depth is 3,000 metres. With 700 millimetres diameter, bores can be sunk down to a depth of 700 metres.
Deep drilling rigs in various sizes for any application Alongside their core functions of drilling for oil and gas, Bauer deep drilling rigs are also equipped to handle other applications. Geothermal is a lucrative form of energy. Moreover, in many countries around the world it is possible to extract the gas continually being produced by coal from underground seams. Fracking also uses machinery of this kind.
Bauer deep drilling rig in operation in Venezuela
This first Bauer deep drilling rig has been sold to Venezuela, where it is being successfully deployed. The range has since been extended with higher and lower end models. The TBA 200 is a smaller version, capable of drilling down to 3,000 metres. The TBA 100 was designed as a highly mobile rig for depths down to around 2,000 metres. A technical interlinking of the feed mechanism and winch turned the TBA 300 into a TBA 440. A new TBA 440 M2 with an automated pipe handler for duplex strings is currently under construction. Another of the smaller deep drilling rig models is the RB-T 90. Six of these 100 short-ton class universal drilling rigs were sold to China in Autumn 2012. They are designed to sink emergency rescue shafts to reach trapped miners quickly and safely. A key feature of the newly developed machine is its great mobility: Built on a truck trailer, it can be towed quickly to any location
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NEWS & REPORTS BAUER Maschinen GmbH
Safely roped-up – Safety system on boom
Safely roped-up – Safety system on boom Mountaineers know that on difficult routes it is best to be roped-up. Other hazardous trades also work with safety ropes – such as facade cleaning contractors. It is a similar method which Bauer Maschinen employs to secure a hazardous cable excavator operation. Personnel climbing on the boom – at heights above two metres! – during erection and disassembly work were previously provided with inadequate protection. DIN EN ISO 2867 : 2011 -11 stipulates that a fall guard must be mounted on the boom all along its length. Instead of mounting expensive railings, Bauer‘s designers came up with a more cost-effective solution: A steel rope is strung across the entire length of the boom at a height of about two metres above the walkway from the hydraulic winch on the gantry to the swivel arm mounted on the boom head. Personnel are protected from falling by attaching a safety harness to the steel rope.
FOR MORE INFORMATION AND CONTACT: BAUER AG BAUER-Straße 1 | 86529 Schrobenhausen P.O. Box 12 60 | 86522 Schrobenhausen Tel: +49 8252 97-0 | Fax: +49 8252 97-1359 eMail: info@bauer.de | Internet: www.bauer.de
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The BAUER Group is an international construction and machinery manufacturing concern based in Schrobenhausen, Bavaria. The stock-market listed holding company BAUER Aktiengesellschaft is the parent of more than 110 subsidiary businesses in the fields of construction, equipment and resources. Bauer is a leader in the execution of complex excavation pits, foundations and vertical seals, as well as in the development and manufacture of related machinery for this dynamic market. The Group also deploys its expertise in the exploration, mining and safeguarding of valuable natural resources. In 2012 the companies of the BAUER Group employed about 10,300 people in some 70 countries and achieved total Group revenues of EUR 1.45 billion.
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NEWS & REPORTS Sandvik Construction Central Europe
As the going gets tough, Sandvik get tougher: the new RH460 series of DTH hammers andvik Constructionâ&#x20AC;&#x2122;s extensive range S of rock tools are world renowned for combining advanced materials technology,
with skillful design focusing on performance, simplicity and endurance. The latest member of the range is the RH460 series of down-the-hole hammers, which have been developed to give customers even higher levels of productivity and reliability, whilst simultaneously delivering lower operating costs. RH460 DTH hammer
The new Sandvik RH460 series of DTH hammers has been developed in order to provide drilling customers with the enhanced levels of penetration rates, longer service life and lower operating costs that they now demand. Possessing key features that optimize the impact-energy transmission into the rock, utilizing very few parts, they are designed to be reliable, easy to service, and fast. Continuous improvement has been the key to the development of the Sandvik RH460 series, and it has only been through the constant search for enhanced performance, through productivity, that has allowed Sandvik to deliver the operational improvements our customers demand from their DTH hammers. Thus, with the RH460 Sandvik is able to provide customers with higher impact energy and drill performance, whilst maximizing productivity in almost all ground conditions.
RH460 DTH hammer
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NEWS & REPORTS Design, test and evaluate The mantra behind the design has been to test and evaluate; this has led to the RH460 design being able to prolong hammer life and increase drilling penetration rates. At its core is the ability of the RH460 to utilize an enhanced air cycle which leads to a reduction in fuel consumption. Furthermore, power levels improve productivity through better lubrication capabilities and increased resistance against galling; all combined with developments in the piston bearing design. Put quite simply; piston and hammer life are dramatically increased.
The new Sandvik RH460 series hammers will be available in 4”, 5” and 6”, with all versions being designed to utilize bits with generic shank types. The uncompromising nature of the design, and the development of the concept being focused on operational efficiencies, will ensure that this ground breaking range of DTH hammers fulfills Sandvik’s commitment to - when the going gets tough, Sandvik gets tougher.
Contact: Sandvik Construction Emilie El Tarzi Marketing Communications Specialist Tel: +46 (0) 26 26 23 26 eMail: emilie.eltarzi@sandvik.com
RH460 DTH hammer
Sandvik is a global industrial group with advanced products and worldleading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK Sandvik Construction Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunnelling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees.
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NEWS & REPORTS Sandvik Construction Central Europe
New Premium QI441 PriSec Impactor offering unparalleled flexibility and performance as a primary or secondary crusher
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andvik Mobiles are proud to announce the launch of the new QI441 Impactor which features the unique PriSec crushing chamber. This development further enhances Sandvik’s extensive, and extremely versatile, crusher portfolio.
The QI440 is already proven in its class for offering superb product shape, high productivity and ease of maneuverability. The new Premium QI441 model is now set to offer customers unparalleled flexibility in both primary and secondary applications through the use of the revolutionary CI421 PriSec Impactor box. The patented PriSec crushing chamber has been designed by Sandvik to enable the base crusher to be easily switched between primary and secondary mode, thereby giving the customer virtually two machines from one unit. The two hydraulically assisted curtains can be readily adjusted to allow the production of a wide range of high quality product sizes. The new QI441 model also retains many beneficial features introduced on the QI440 such as: • • • • • • •
Direct drive system for optimum fuel economy and low operating costs Large feed hopper with highly efficient pre-screening Underpan feeder to protect the main product conveyor from high velocity material from the rotor User friendly PLC control system and color screen for ease of operation Inlet opening may be raised by remote control to alleviate blockages Overband magnet, pre-screen, natural fines conveyor, ceramic blow bars and remote control as standard Low wear, easy maintenance and a low cost per ton operation.
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The versatility of the QI441 is further ensured by a comprehensive range of optional extras that allows the crusher to precisely match the demands of the customer’s specific application; these include a unique Doublescreen double-deck hanging screen with recirculation system. This is of particular benefit as conventional hanging screens are often a limiting factor with high capacity impactors, forcing the customer into an expensive secondary screen purchase. However, the on-board Doublescreen system is designed to match the maximum capacity of the crusher, thus allowing the production of accurately sized products for immediate use at source from one machine. The QI441 PriSec is the latest addition to Sandvik’s Premium range of tracked impact crushers, providing customers with an extensive mobile crushing solution whatever the application. Available in a heavy duty and compact format, all models possess high reduction ratios giving customers the best possible product shape, high productivity, low wear, easy maintenance and a low cost per ton. Sandvik’s Premium range of tracked impact crushers provides customers with an extensive mobile crushing solution whatever the application; from small inaccessible recycling sites to large quarrying applications. Both models possess high reduction ratios giving customers the best possible product shape, high productivity, low wear, easy maintenance and a low cost per ton.
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NEWS & REPORTS Sandvik Construction Central Europe
The New Premium QE341 – The ultimate heavy duty scalping system As part of our commitment to ongoing product development Sandvik is proud to launch the new QE341 heavy duty scalper
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he new QE341 combines 10 years of experience and customer feedback in the mobile scalper market with well over 100 years’ experience in moving materials in the mining industry. A decade on from its first launch, the QE340 has been redesigned to offer a more refined unit, that is more robust and offers increased throughput. The QE341 has been developed with easier setup, operation & maintenance in mind. The key customer requirements have all been addressed with the new model: • • • • • • • •
Stockpiling capacity - increased discharge heights and conveyor lengths means up to 50% more stockpiling capacity Ability to handle the biggest infeed - heavy duty apron feeder with increased hopper width Free-flow of material with no bottle necks - increased width and capacity of oversize conveyor Ease of operation - new colour-coded control panel with sequential start up High production - 20% increase in hopper capacity and the uniquely aggressive screenbox action ensure maximum productivity Ease of maintenance - screenbox can be raised for bottom deck change, larger and more accessible maintenance platforms Safety - compliant with the latest Machinery Directives Mobility - improved set-up time with hydraulically folding platforms and one-piece rigid hopper
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•
Continuity - all screening media from QE340 are compatible with the QE341.
The new QE341 complements the larger QE440 within the Premium Scalper range. The QE341 also features a robust crusher-style chassis, and has been designed to be compatible for 2-way or 3-way split configurations along with reversible side conveyors demonstrating the ultimate flexibility of the unit. The screen box jack up facility, also common with the QE440, allows easier access to the bottom deck for maintenance and screen media changes. One of the major upgrades to the model is the new electrical control system which incorporates a number of features to improve both the operational effectiveness and safety of the machine. The simple easy to use system has colour-coded numerical push buttons and a visual display unit allowing the operator to fully monitor the process. Prestart warnings on all plant functions and an auto start / stop facility together with a three mode selector function;
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NEWS & REPORTS set-up, operation and tracking facility, all ensure that safety, as well as ease of operation, is paramount at all times. The unit is fully radio controlled as standard. Ideal for contractors requiring the need to travel quickly from site to site, the unit has hydraulically folding tail and side conveyors and now has a rigid one-piece hopper designed for quicker set-up times and improved tail drum ground clearance for tracking. These new features are aimed at ensuring the QE341 is now as user and environmentally focused as it is productive, efficient and versatile and will soon become the ultimate scalper of choice within the construction and aggregates industries.
Sandvik is a global industrial group with advanced products and world-leading positions in selected areas â&#x20AC;&#x201C; tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK Sandvik Construction Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunnelling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees.
Contact: Sandvik Construction Melissa Baker Marketing Communications, Mobile Crushers and Screeners Tel. +44 (0) 1283 212121 eMail: melissa.baker@sandvik.com
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NEWS & REPORTS Sandvik Construction Central Europe
One crusher, two configurations Sandvikâ&#x20AC;&#x2122;s New Prisec TM CI5** Series HSI
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he new generation of compact horizontal impact crushers (HSI) from Sandvik provides customers with a low capital cost solution, optimum performance and good cubical shape, whilst ensuring the lowest operating cost per ton for a wide range of materials and applications. The all new patented and highly modularized Sandvik CI5** Prisec TM crusher range, additionally combines the ability to configure one base crusher into either a Primary or a Secondary configuration, thereby making it adaptable to ever-changing requirements. The new Horizontal Shaft Impactor (HSI) range of crushers from Sandvik Construction have been developed in response to customer demands, building on the rock solid foundation of the primary and secondary series they will replace. Spearheaded by the CI511, this new range of crushers establish Sandvik as market leaders in the design and development of HSI crushers that have been developed to deliver exceptional rates of productivity and efficiency. All crushers possess the ability to be configured into either a primary or secondary crusher operating mode and with this unique, exclusive to Sandvik, patented design, provides customers with unparalleled adaptability.
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Exceptional reduction ratios Sandvikâ&#x20AC;&#x2122;s revolutionary all new design of crushing chamber ensures even greater reduction ratios than have been previously obtainable. Furthermore the Prisec TM crusher is able to easily produce impressive reduction ratios through the use of two uniquely designed curtains, which have traditionally required a three curtain configuration crusher. As well as enhanced productivity, this means fewer wear parts and reduced maintenance.
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NEWS & REPORTS
combined downtime and health and safety risks encountered, are now eliminated with the Sandvik new generation Prisec TM crusher. Due to the exceptional features of the crushers no stopping of the crusher is necessary, with no operator intervention inside the crusher, no heavy lifting gear required, all resulting in maximum uptime and reduced health and safety problems.
Rotor and hammer design The rotor and hammers can be considered as the heart of the crusher; this is why those used on the CI5** Prisec TM range are both robust and efficient. Rotors have superior weight and design, essential for delivering the high inertia required for optimum crusher performance, thus ensuring stability and smooth operation during production. The unique “banana” shaped self-sharpening hammer design helps to keep the contact heads sharper during operation, resulting in more effective shearing of the incoming material, and hence improved production.
Energy efficient overload protection
Easy and Safe maintenance
The CI511 Prisec TM is equipped with an infinite hydraulic curtain adjustment combined with a brake positioning system which relieves pressure, and setting, when un-crushable objects enter the crusher. No hydraulic power is required during normal operation, thus saving on operating power and reducing total power consumption. Both first and second curtains are infinitely adjustable via the Sandvik’s patented adjustment / braking system which is located on the cross beams of the crusher. This system gives hydraulic adjustment of both curtains, via the standard supply electric hydraulic power pack.
A unique key safety interlock system ensures safe maintenance of the crusher and prevents accidental opening of the crusher and inspection doors even in multiple installations. It also allows the ability to raise curtains during operation without stopping the crusher to clear blockages, and re-set automatically to operating setting. This maximizes uptime and reduces the need for heavy lifting gear and operator / maintenance intervention, thereby reducing further Health & Safety risks.
Dealing with crusher blockages
Through the modularized nature of the Prisec TM range, wear parts can be turned for maximum life/usage with the same size being used across the whole range of crushers. In addition, Sandvik’s world leading technology in the hammer and liner material composition provides options
Crusher blockages have always historically been a problem, especially when operating in a primary configuration. Removal of the blockage, with the
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Maximum uptime, Maximum breakage
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NEWS & REPORTS far surpassing old industry standard of manganese, resulting in even lower operating cost per ton and the ability to operate efficiently in a variety of materials, especially recycling applications.
Sandvik is a global industrial group with advanced products and world-leading positions in selected areas â&#x20AC;&#x201C; tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK Sandvik Construction Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunnelling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees.
Technical Data Rotor diameter (mm) Max. feed size (mm) Rotor configuration Tonnage throughput (nominal)
CI511 â&#x20AC;&#x201C; Prisec TM crusher 1005mm High x 950mm wide 600mm Open Type, 4 hammer. 200 TPH
Contact: Sandvik Construction Rowan Dallimore, Product Manager Impact Crushers Stationary Crushing and Screening Tel: +44 1761 239249 eMmail: rowan.dallimore@sandvik.com
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NEWS & REPORTS Sandvik Construction Central Europe
Sandvik Construction develop brand new cone crusher CH550
he new generation of compact cone crusher from Sandvik provides customers with T optimum performance and good cubical shape, whilst ensuring the lowest operating cost per ton for a wide range of materials and applications. The all new patented Sandvik CH550 is based on the proven HYDROCONE TM design, with the CH550 combining the ability to produce excellent shaped products, in fewer crushing stages, thereby making it adaptable to ever-changing customer requirements. The new CH550 crusher from Sandvik Construction has been developed in response to customer demands, building on the rock solid foundation of the HYDROCONE TM concept. This new range of crushers establishes Sandvik as market leaders in the design and development of cone crushers that have been developed to deliver exceptional
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rates of productivity and efficiency. The CH550 crusher has the ability to be configured for either secondary or tertiary crusher applications. It also has a wide performance range and with its unique, patented design the CH550 provides customers with unparalleled adaptability and flexibility.
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NEWS & REPORTS Excellence in quality and performance In order to facilitate greater reduction ratios, efficiency and productivity than have been previously obtainable, the new CH550 comes with market leading features: • • • • •
Sophisticated design with remarkable capacity in relation to size. The CH550 is versatile; one of three eccentric bushings will cover 90% of the application range. The Automatic Setting System, ASRi, is included as standard to guarantee safe usage as well as optimal material reduction and shape. The wear parts have been adapted ensuring a longer lifetime per ton produced. Effective power transfer capability thanks to new drive arrangements that gives a precise lining of the V-belts, and more than five times prolonged life time.
A greener choice In order to minimize negative environmental impact, and to produce safer working conditions, the CH550 comes with no plastic backing; furthermore the motor has the highest energy efficiency classification, resulting in less power consumption, thereby minimizing Co2 emissions. Compared to earlier models, these features enable the crusher to reduce emissions by approximately 30 tons each year; equivalent to six persons annual emissions , as well as saving’s on operating power, thereby reducing total power consumption during the crushers operational lifetime.
Safe Operation
Sandvik is a global industrial group with advanced products and world-leading positions in selected areas – tools for metal cutting, equipment and tools for the mining and construction industries, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems. In 2012 the Group had about 49,000 employees and representation in 130 countries, with annual sales of more than 98,000 MSEK Sandvik Construction Construction is a business area within the Sandvik Group providing solutions for virtually any construction industry application encompassing such diverse businesses as surface and underground rock quarrying, tunnelling, excavation, demolition, road building, recycling and civil engineering. The range of products includes rock tools, drilling rigs, breakers, bulk-materials handling and crushing and screening machinery. In 2012 sales amounted to more than 9,700 MSEK, with approximately 3,300 employees.
Contact: Sandvik Construction Martin Johansson, Product Line Manager Stationary Crushing and Screening Tel: +46 40 40 68 34 eMail: martin.johansson@sandvik.com
In order to safely maximize operational uptime the CH550 comes with Sandvik’s leading ASRi fitted as standard. This Automatic Setting System - ASRi - enables the crusher to run at maximum performance levels, the ASRi adjusts automatically to the variations in feed conditions for an ideal final product.
Technical Data Weight (ton) Available Power(kW) Head diameter (mm)
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CH550 18,9 ton 330kW. ~1100mm
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NEWS & REPORTS Voith Turbo GmbH & Co. KG
Voith: The right Voith drive solution for every belt conveyor
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oith recently delivered 36 fluid couplings for an iron ore distribution center in Malaysia. Starting in 2014, the couplings will be used in the drives of 16 belt conveyors supplied by the BEUMER Group. For each of the belt conveyors Voith has offered just the right fluid couplings.
The supplied Voith hydrodynamic fluid couplings are applied to drives ranging in powers from 200 to 800 kW. They have been selected to softly start and protect all conveyor system components and minimize unplanned system downtime. Voith fluid couplings have a rugged design and are well suited for use under the most extreme environmental conditions. They dampen torsional vibrations in the driveline and protect it against overload. This extends the lifetime of the entire system. Voith has offered just the right fluid couplings for each of the 16 belt conveyors. The belt conveyor drives are equipped with TVVS-type couplings. Voith is delivering special TVVS designs to match the start-up and operating conditions of the drives.
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The TVVS constant-filled fluid coupling is particularly suited for medium and long belt conveyors with start-up times up to 45 seconds. Fluid couplings automatically match the demand torque of the driven conveyor. The smooth application of fluid coupling torque provides a smooth belt start-up to protect the belt from damaging stresses, thus reducing system downtimes. Thanks to the mechanical separation of the motor and machine through the fluid coupling, the motor can run up to speed without load. In addition, systems that use multiple motors can be switched on in a staggered sequence to limit the current demanded during the motor acceleration. This avoids grid overloading caused by simultaneous motor starts. In the most demanding belt conveyors, the TVVS is deployed with centrifugal force valves to further
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NEWS & REPORTS protect the electric grid. Centrifugal valves control the filling and draining of the coupling working circuit, and thus the power transmission, as a function of the drive speed. The motor starts up virtually load-free, even in the event of voltage drops. The coupling torque is applied continuously and without shocks up to the required breakaway torque of the system. The TVVS can also use water as the operating medium. This environmentally-friendly operating medium is particularly well-suited for use in the belt conveyors that transport iron ore above the ocean. In future, the Malaysian iron ore distribution center will supply customers in the Asian- Pacific region with iron ore from South America. The belt conveyors transport the iron ore from the terminal to the harbor. The reliability of the belt conveyors is extremely important for ensuring the planned shipment capacity. Voith drive solutions increase the availability of these belt conveyors.
About Voith Turbo Voith Turbo, a division of Voith GmbH, specializes in hydrodynamic drive, coupling and braking systems for road, rail and industrial applications, as well as for shipboard propulsion systems. Voith sets the standards in the energy, oil & gas, paper, raw materials and transportation & automotive markets. Founded in 1867, Voith now employs more than 42,000 people, generating â&#x201A;Ź5.7 billion in sales and operating in some 50 countries in every region of the world, making it one of the largest family-owned companies in Europe today. FOR MORE INFORMATION AND CONTACT: Voith Turbo GmbH & Co. KG Voithstr. 1 74564 Crailsheim | Germany Tel.: +49 (0) 7951 32-429 Fax: +49 (0) 7951 32 665 Internet: www.voith.com
Alena Eisele Tel: +49(0) 7951 32-429 eMail: alena.eisele@voith.com
The Voith constant-filled fluid coupling protects the components in belt conveyor systems, increasing their availability.
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NEWS & REPORTS TAKRAF GmbH
TAKRAF inaugurates erection site in India: 5.400 tons to be mounted for two large-scale bucket wheel excavators within 24 months
5.400 tons to be mounted for two large-scale bucket wheel excavators within 24 months. The excavators are scheduled to go into operation in July 2015. (Source: TAKRAF GmbH)
With a symbolic laying of the first crawler pads the erection has been started by end of May this year – only 11 months after the award and ahead of the contractual. The inauguration in Neyveli, India, started with a traditional “Pooja” by a Hindu priest, blessing the erection site and the workers. Around fifty esteemed guests from Neyveli Lignite Corporation, TAKRAF India as well as some main subcontractors were following the invitation. During the next almost 24 months two largescale bucket wheel excavators will be erected With a symbolic laying of the first crawler pads the erection has been started by end of May this year in Neyveli, India. (Source: TAKRAF GmbH)
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NEWS & REPORTS and installed comprising of around 5400T of structural steel, mechanical components and electrical systems. The excavators have a theoretical output of 5.460 m³/hr each for removing overburden. In the peak periods more than 200 people will be working on this project site under the supervision of TAKRAF India. The excavators are scheduled to go into operation in July 2015
With a traditional “Pooja” by a Hindu priest, the erection site and the workers got blessed during the inauguration. (Source: TAKRAF GmbH)
FOR MORE INFORMATION AND CONTACT: TAKRAF GmbH Torgauer Straße 336 04347 Leipzig | Germany Tel.: +49 (0) 341 24 23 5 00 Fax: +49 (0) 341 24 23 5 10 eMail: sales@takraf.com Internet: www.takraf.com Press Agency Gebhardt-Seele Leonrodstraße 68 80636 München | Germany Tel.: +49 (0) 89 500315-0 Fax: +49 (0) 89 500315-15 eMail: pressebuero@gebhardt-seele.de Internet: www.gebhardt-seele.de
Background The roots of TAKRAF GmbH are dating back to the early 18th Century, when the production of simple steel tools started. Until the end of the century, the company has developed to a renowned machinery manufacturer. In the early 1920s, tendencies towards open cast lignite mining became visible, which then was a main focus of the Lauchhammer works in Brandenburg. Here the first bucket wheel excavator was developed which was considered to be the century’s most important invention. From now on, the continuous removal and transportation of overburden and lignite via belt conveyors became possible. After World War II, the company was nationalized and was was forced by the isolated position of the GDR to contribute to the development of the domestic economy with the result that the maximum size of machines was reached in the 1980’s. The company had to be reorganized after the reunification to adapt to new conditions: large-scale redundancies and shut-down of unprofitable locations were the consequences. Leipzig and Lauchhammer were kept as business locations until today. With the growing importance of exports, TAKRAF established the first foreign subsidiaries in the mid 1990’s. Today, TAKRAF GmbH maintains its own subsidiaries and representative offices all over the world. The largest single market is Chile, where 20 to 25 percent of business volume is generated in open-cast copper mining. Since 2008 TAKRAF GmbH is a fully owned subsidiary of the Italian Tenova Group and integrated there in the Mining and Minerals Division.
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NEWS & REPORTS K+S Aktiengesellschaft
K+S increases capital expenditures for new potash plant in Canada
• Basic engineering of the Legacy Project further advanced • Supervisory Board agrees to decision of the Board of Executive Directors for raising the capex budget to 4.1 billion CAD • Production capacity of 2 million tonnes will be available as planned by 2017 • Commissioning in summer of 2016 (so far end of 2015) expected • Financing of the still economically attractive and strategically important potash project secured
New potash plant in the Canadian province K+S is committed to continuing the construction of the new potash plant in the Canadian province of Saskatchewan. This includes the basic engineering and cost analysis of the major subprojects which is now at an advanced stage. The Supervisory Board which is always promptly and closely involved in all phases of the project has approved the decision of the Board of Executive
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Directors to increase the capex budget for the new plant to 4.1 billion CAD (about 3 billion €). The so far assessed 3.25 billion CAD were based on the feasibility study conducted in November 2011. The now presented plan includes investments into K+S’s own infrastructure, modifications of plant components and infrastructure as well as increased material and labor costs. The adjustments to the budget were identified in a very early stage of the project. “The additional findings strengthen the predictability, transparency and controlling as well as our major project overall,” says Norbert Steiner, Chairman of the Executive Board of Directors of K+S. “In the future, the new plant will be the main source for distributing to the emerging regions in Asia, South America and as well to North America. Legacy strengthens the K+S Group’s competitiveness and opens attractive prospects for many decades,” Steiner emphasizes. “Legacy is an important part of the future of K+S. Taking all data of the profitability calculation into account the project is economically attractive and still fulfills the requirement of
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NEWS & REPORTS the Group, to earn a 15% premium on the cost of capital before taxes. The K+S Group has a solid balance sheet. The Financing will be ensured by existing liquidity, future cash flows and new debt. “The dividend policy of the company will remain unaffected by the decision to increase the capital expenditure,” Steiner concludes. With the expected commissioning in summer 2016 the company still projects to reach the two-million-tonnesmark of production capacity at the new location at the end of 2017. The gradual extension of the annual capacity to 2.86 million tonnes of potash products will occur afterwards. So far the company assumed a production start at the end of 2015. The annual production capacity of the existing K+S sites is up to 7.5 million tonnes of potash and magnesium products.
About the Legacy Project Legacy is a greenfield project for the setting up of a potash production on the basis of solution mining in the south of the Canadian province of Saskatchewan. With Legacy K+S will be the only potash producer with large and own production facilities on two continents. The new potash plant will complement the German production network, reduce the average production costs and extend the average lifetime of the mines. In addition, Legacy will
strengthen K+S’s competitiveness significantly which will bolster the total K+S Group as a result. More information about the Legacy Project at www.ks-potashcanada.com.
Experience growth K+S is one of the world‘s leading suppliers of standard and speciality fertilizers. In the salt business, K+S is the world’s leading producer with sites in Europe as well as North and South America. K+S offers a comprehensive range of goods and services for agriculture, industry, and private consumers, which provides growth opportunities in virtually every sphere of daily life. Worldwide, the K+S Group employs more than 14,000 people. The K+S share – the commodities stock on the German DAX index – is listed on all German stock exchanges (ISIN: DE000KSAG888, symbol: SDF). More information about K+S at www.k-plus-s.com.
FOR MORE INFORMATION AND CONTACT: K+S Aktiengesellschaft - Investor Relations Thorsten Boeckers Tel.: +49 (0) 561 9301-1460 Fax: +49 (0) 561 9301-2425 eMail: thorsten.boeckers@k-plus-s.com K+S Aktiengesellschaft - Press Michael Wudonig Tel.: +49 (0) 561 9301-1262 Fax: +49 (0) 561 9301-1666 eMail: michael.wudonig@k-plus-s.com
K+S Aktiengesellschaft Corporate Communications Bertha-von-Suttner-Str. 7 34131 Kassel | Germany Tel.: +49 (0) 561 9301-1262 Fax: +49 (0) 561 9301-1666 Internet: www.k-plus-s.com
View at the first well field rig on the Legacy construction site which has been in operation since the beginning of 2013 (Source: K+S).
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NEWS & REPORTS Atlas Copco Construction Tools
Atlas Copco:
HB 4100 breaker used for underwater demolition in Italy
S
ince last August an Atlas Copco HB 4100 hydraulic breaker has been deployed for underwater demolition near Giglio Island, Tuscany, Italy. The work is the first phase of a major maritime engineering operation in which Atlas Copco is closely collaborating with Sales SpA, a well known Italian construction company specializing in infrastructure and maritime projects.
HB 4100 breaker underwater demolition in Italy n
to be used underwater. A safety system immediately stops the stroke of the hammer if, for any reason, the compressor stops injecting compressed air.
For underwater demolition of granite rocks at a depth of ten meters, Sales SpA is using an Atlas Copco HB 4100 breaker , with a machine weight of 4,150 kg, attached to a Liebherr 984 tracked excavator mounted on a floating pontoon. Working â&#x20AC;&#x153; blind â&#x20AC;? in the cabin of the excavator, the operator relies exclusively on a GPS tracking system and instructions from the divers. One single blow with a flooded stroke chamber would damage the breaker. Therefore, to enable the HB 4100 to operate effectively underwater it is partnered with an Atlas Copco XAHS186 compressor. The compressor prevents water from entering the machine by blowing in compressed air. Channels for compressed air are standard on Atlas Copco hydraulic breakers, enabling them
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NEWS & REPORTS Gordon Hambach, Product Line Manager Hydraulic Breakers, points out that Atlas Copco has extensive experience of dredging, excavation and underwater demolition in harbours, rivers, and canals. “ We are working on projects of this type with a number of companies around the world and can offer a customized package comprising breaker and compressor, depending on water depth and breaker size. Customers are always welcome to discuss their specific needs with our specialist sales and technical personnel located at our Customer Centers throughout the world. ” Atlas Copco showcased the new HB 4100 last spring at the Paris trade fair. Compared to the previous model, the HB 4100 has been upgraded to offer considerably more power with greater energy efficiency and reliability. The breaker also has all the advanced functions that customers have come to expect from attachments in Atlas Copco’s range of heavy hydraulic breakers, such as VibroSilencing, the PowerAdapt system, which turns off the breaker in the event of hydraulic overloading, AutoControl, which adjusts stroke frequency and impact energy to the hardness of the rock, and the automatic lubrication system ContiLubeTM II series.
Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment systems, construction and mining equipment, power tools and assembly systems. With innovative products and services, Atlas Copco delivers solutions for sustainable productivity. The company was founded 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2012, Atlas Copco had about 39800 employees and revenues of BSEK 90,5 (BEUR 10,5 ). Atlas Copco Construction Tools is a division within Atlas Copco´s Construction Technique business area. It develops, manufactures and markets hydraulic, pneumatic, and petrol-driven equipment for demolition, recycling, compaction, rock drilling and concrete applications. Products are marketed and sold under several brands through a worldwide sales and service organisation. The division is headquartered in Essen, Germany, and has production units in Europe, Africa and Asia. In 2013 Atlas Copco, ranked as one of the most innovative, sustainable and ethical companies in the world, celebrates 140 years of profitable growth. At the beginning the company made products for railways, but the core of Atlas Copco’s business dates back to the early years of the 20th century when the first compressors, tools and rock drills were manufactured. Today, the Atlas Copco Group has world-leading positions in these areas and many others. Atlas Copco supports customers in 180 countries with own operations in 90 countries. Read the story about a company that believes ‘there is always a better way’ on Atlas Copco History.
FOR MORE INFORMATION AND CONTACT: Atlas Copco Construction Tools Communications & Training Manager Anja Kaulbach eMail: anja.kaulbach@de.atlascopco.com Internet: www.atlascopco.com
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ADVERTISMENT
NEWS & REPORTS
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EVENTS
2013
THE AMS-EVENT CALENDER July 2013 01 - 03 Jul The Australian Mine Ventilation Conference 2013
Adelaide, Australia
www.austminevent.com.au
01 - 03 Jul Pre-Geoforum 2013 IOCG Short Course
Johannesburg, South Africa www.rca.co.za/geoforum2013
02 - 04 Jul Copper China 2013
Shanghai, China
03 - 05 Jul GeoForum 2013
Johannesburg, South Africa www.rca.co.za/geoforum2013
05 - 07 Jul 11th International Council for Applied Mineralogy (ICAM) Congress
Mianyang, China
www.icam2013.org
Hong Kong, China
www.icges.org
09 - 11 Jul Africa Mining Investment & Development Summit 2013
Accra, Ghana
www.neo-edge.com
09 - 10 Jul Coal Market in India 2013
New Delhi, India
www.ibkmedia.com
Aachen, Germany
www.abk.gdmb.de
15 - 16 Jul Mozambique Coal Conference
Maputo, Mozambique
www.immevents.com
16 - 18 Jul Exploration and Mapping in Mining 2013
Perth, Australia
www.beaconevents.com
17 - 18 Jul NSW Mineral Exploration and Investment Conference
Sydney, Australia
www.tmm.com.au
06 - 07 Jul
16. Jul
2nd International Conference on Geological and Environmental Sciences ICGES 2013
15. ABK - Aachener Altlasten- und Bergschadenkundliches Kolloquium "Frackingdiskussion und kein Ende"
www.aluminiumchina.com/en/Copper-China
24 - 26 Jul Geomin 2013 3rd International Seminar on Geology for the Mining Industry Santiago, Chile
www.geomin2013.com
24 - 26 Jul Mine Planning 2013 3rd International Seminar on Mine Planning
Santiago, Chile
www.mineplanning2013.com
30 Jul - 01 Aug 32nd International Conference on Ground Control in Mining
Morgantown, USA
www.icgcm.conferenceacademy.com
31 Jul - 01 Aug The Deep Sea Mining Summit 2013
London, UK
www.deepsea-mining-summit.com
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EVENTS
2013
THE AMS-EVENT CALENDER August 2013 04 - 09 Aug
The 8th Pacific Rim International Conference on Advanced Materials and Processing
Waikoloa, USA
www.tms.org
05 - 09 Aug IMWA 2013 Reliable Mine Water Technology
Golden, USA
www.csmspace.com/events/imwa2013
06 - 08 Aug Australian Coal Mining Expo 2013
Brisbane, Australia
www.acmeminingexpo.com
06 - 09 Aug XVIII Simposium de IngenierĂa en Minas SIMIN 2013
Santiago, Chile
www.simin.cl
12 - 14 Aug Iron Ore 2013
Perth, Australia
www.ausimm.com.au/ironore2013
12 - 16 Aug Global Minerals Industry Risk Management (G-MIRM) for Managers (WA)
Perth, Australia
www.jktech.com.au
14 - 16 Aug World Mining and Energy Expo
Miami, USA
www.ibarragarrido.com
18 - 21 Aug Queensland Mining Industry Health and Safety Conference 2013
Jupiters, Australia
www.qrc.org.au
22 - 25 Aug Expo Bolivia Minera 2013
Oruro, Bolivia
www.tecnoeventos.org
San Diego, USA
www.flogen.org/MMM2013
26 - 28 Aug Mine Maintenance and Reliability 2013
Brisbane, Australia
www.ibrc.com.au
22 - 23 Aug Asia-Pacific's International Mining Exhibition (AIMEX 2013)
Sydney, Australia
www.aimex.com.au
15th IFAC Symposium on Contrl, Optimization and Automation in Mining, 25 - 28 Aug Mineral & Metal Processing (MMM2013)
San Diego, USA
www.flogen.org/MMM2013
25 - 28 Aug
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MMM2013: 15th IFAC Symposium on Control, Optimization and Automation in Mining, Minerals and Metals Processing
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EVENTS
2013
THE AMS-EVENT CALENDER September 2013 04 - 07 Sep Mining Indonesia 2013 05 Sep Rohstofftag
Jakarta, Indonesia
www.pamerindo.com
Hanover, Germany
www.bgr.de
05 - 07 Sep recycling aktiv 2013
Karlsruhe, Germany
www.recycling-aktiv.com
05 - 07 Sep TiefbauLive 2013
Karlsruhe, Germany
www.tiefbaulive.com
04 - 06 Sep China International Mining Expo CIME 2013
Beijing, China
www.asmr.us
09 - 11 Sep Near Surface Geoscience 2013
Bochum, Germany
www.eage.org
10 - 11 Sep CeMat Hafenforum 2013
Hamburg, Germany
www.cemat.com
10 - 12 Sep Rare Earth Elements and Compounds Conference 2013
Muenster, Germany
www.reec-conference.eu
11 - 13 Sep The Pilbara Mining and Resource Expo 2013
Karratha, Australia
www.pilbaraminingexpo.com
11 - 12 Sep EuroMining Trade Fair 2013
Tampere, Finland
www.euromining.fi
11 - 13 Sep Zimbabwe Mining Indaba 2013
Harare, Zimbabwe
www.zimminingindaba.com
12. Sep Jahrestagung Vereinigung Rohstoffe und Bergbau
Berlin, Germany
www.v-r-b.de
Swieradow Zdroj, Poland
www.minproc.pwr.wroc.pl/mec2013
Aachen, Germany
www.ism-germany-2013.de
16 - 20 Sep PERUMIN – 31st Mining Convention
Arequipa, Peru
www.camese.org
23 - 26 Sep The International Mining Exhibition (EXPOSIBRAM) 2013
Belo Horizonte, Brazil
www.exposibram.org.br
25 - 26 Sep 18. Fachtagung Schüttgutfördertechnik Magdeburg 2013
Magdeburg, Germany
www.ilm.ovgu.de/schuettgut
Karlsruhe, Germany
www.recycling-aktiv.com
Bochum, Germany
www.eage.org
Hamburg, Germany
www.cemat.com
16 - 20 Sep XV International Society for Mine Survey Congress
Aachen, Germany
www.ism-germany-2013.de
25 - 26 Sep 18. Fachtagung Schüttgutfördertechnik Magdeburg 2013
Magdeburg, Germany
www.ilm.ovgu.de/schuettgut
Munich, Germany
www.praxisforum-geothermie-bayern.de
Hanover, Germany
www.norddeutsche-geothermietagung.de
16 - 19 Sep Mineral Engineering Conference MEC2013 16 - 20 Sep
XV International Society for Mine Survey Congress | ISM 2013 - XV International ISM Congress
Event-Highlights 2013 05 - 07 Sep
recycling aktiv 2013
09 - 11 Sep Near Surface Geoscience 2013 10 - 11 Sep
07 - 09 Okt 23 - 24 Okt
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CeMat Hafenforum 2013 Praxisforum Geothermie.Bayern 6. Norddeutsche Geothermietagung
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EVENTS
15. Aachener Altlasten- und Bergschadenkundliches Kolloquium (ABK) am 16. Juli 2013 in Aachen
Advanced Mining Academy
Das Thema Fracking, das schon der Gegenstand früherer Kolloquien war, ist mittlerweile in aller Munde. In den USA erfolgt ein vielfacher Einsatz, der die USA vom Energieim- zum -exporteur werden ließ. Hierzulande soll dagegen nur ein schrittweises Vorgehen in Betracht kommen. Die derzeit vorliegenden Fakten reichen nicht aus, um mögliche Risiken abschließend bewerten zu können. Die mit der Thematik beauftragten Gutachter von UBA und NRW schließen den Einsatz von Fracking jedoch nicht generell aus. Überdies soll nicht das Wirtschaftsressort zuständig sein, sondern das Umweltministerium. Ist diese zurückhaltende Bewertung technisch und rechtlich gerechtfertigt? Sind nicht bergbauliche Vorhaben generell mit Unsicherheiten behaftet? Sollte nicht vielmehr eine sachliche UVP darüber entscheiden, ob eine Frackingbohrung zulässig ist? Inwieweit lassen sich Erfahrungen aus den USA und auch hierzulande nutzbar machen, um eine Förderung unkonventioneller Erdgasvorkommen an dafür geeigneten Standorten zu betreiben? Ist Fracking damit nicht doch schon jetzt genehmigungsfähig, zumindest aber abschließend beurteilbar?
Weiterbildungsprogramm Mining Eine praxisorientierte modulare Ausbildung für Fach- und Führungskräfte der Bereiche Mineralische Rohstoffindustrie Maschinenindustrie Rohstoffhandel Finanzsektor Dienstleistungssektor
Das 15. ABK am 16.7.2013 wird diese Fragen aufgreifen und zur Diskussion stellen.
Kontakt: AMA - Advanced Mining Academy Albrecht-von-Groddeck-Str. 3 38678 Clausthal-Zellerfeld Telefon: +49 (0) 53 23 - 98 39 38 Telefax: +49 (0) 53 23 - 96 29 908 eMail: academy@advanced-mining.com
Das aktuelle Programm sowie das Anmeldeformular finden Sie unter:
http://abk.gdmb.de/abk_XV.pdf
ANZEIGE
www.advanced-mining.com/academy
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EVENTS
ADVERTISEMENT
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EVENTS
CeMAT Hafenforum in Hamburg
Deutsche Messe Messegelände
10. & 11.09.2013
30521 Hannover Germany Tel. +49 511 89-0 Fax +49 511 89-32626 info@messe.de
Ans
Dan Proj Tel. Fax
dan
www.messe.de
Jetzt anmelden unter www.cemat.de/de/hafenforum2013
Häfen der Zukunft – innovativer Zugang zu den Weltmärkten
Ein Event der
cemat.com
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EVENTS
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MediA-partner / EVENTS
Praxisforum geothermie.bayern
Veranstaltungsort
Das Praxisforum geothermie.bayern findet am 8.10.2013 im Haus der Bayerischen Wirtschaft, München statt. Neben dem Kongress werden am 7. und 9.10. Workshops sowie Exkursionen zu Strom- und Wärmeprojekten angeboten.
Das Praxisforum geothermie.bayern findet im exklusiven Konferenzzentrum Haus der Bayerischen Wirtschaft statt. Der Veranstaltungsort liegt zentral in München und ist mit öffentlichen Verkehrsmitteln gut zu erreichen. In der Tiefgarage steht eine begrenzte Zahl an Parkplätzen zur Verfügung. Weitere Parkplätze finden Sie in der Umgebung.
Das detaillierte Programm wird Mitte Juli zur Verfügung stehen. Weitere Informationen finden Sie unter: www.praxisforum-geothermie-bayern.de
Veranstalter Enerchange
Die Veranstaltung verteilt sich auf zwei Konferenzsäle, ausgestattet mit modernster Technik. Aussteller finden im Foyer ausreichend große Repräsentationsflächen. Bei gutem Wetter kann das Atrium von den Teilnehmern entsprechend mitgenutzt werden.
Marcus Brian & Dr. Jochen Schneider GbR Projektverantwortliche: Dr. Jochen Schneider, Dr. Sabine Volland Goethestr. 4 D- 79100 Freiburg Fon: +49 (0)761- 38 42 10 01 Fax: +49 (0)761 - 38 42 10 05 eMail: agentur@enerchange.de Internet: www.enerchange.de
Enerchange ist eine Spezialagentur für PR, Veranstaltungen sowie Informationsund Beratungsdienstleistungen im Bereich Erneuerbare Energien und nachhaltiger Energienutzung. Unser Leistungsspektrum umfasst die Organisation von Veranstaltungen, die Presse- und Öffentlichkeitsarbeit sowie die Recherche und das Publizieren von Fachinformationen.
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MediA-partner / EVENTS
6. Norddeutsche Geothermietagung bietet umfassenden Überblick über aktuelle Herausforderungen innovative Lösungen der Erdwärmenutzung. Vom 23. bis 24. Oktober 2013 findet im Geozentrum Hannover zum sechsten Mal die Norddeutsche Geothermietagung statt. Veranstalter sind die Freiburger Agentur Enerchange, die drei Organisationen des Geozentrums Hannover sowie die Wirtschaftsfördergesellschaft hannoverimpuls. Rund 200 Teilnehmer nutzen die etablierte Veranstaltung jedes Jahr, um sich über Potenziale und innovative Anwendungsmöglichkeiten der oberflächennahen und tiefen Geothermie speziell im Norddeutschen Becken zu informieren. Am ersten Tag befasst sich die Veranstaltung traditionell mit Themen der oberflächennahen Geothermie – in diesem Jahr reichen sie von Qualitätssicherung über beispielgebenden Großprojekten in der Entwicklung bis hin zur Fragen der Wirtschaftlichkeit und Integration in die Städteplanung. Am zweiten Tag steht die tiefe Geothermie im Fokus. Hier geht es unter anderem um die Bereitstellung von geothermischer Fernwärme, die Erschließung der unterirdischen Reservoire, die Finanzierung der Projekte, Machbarkeitsstudien sowie Erfahrungen mit der Nutzung der tiefen Erdwärme. Abgerundet wird die Tagung durch Exkursionen, die Impuls-Lounge am Abend des ersten Tages und eine Podiumsdiskussion zum Spannungsfeld Fracking und Geothermie, an der unter anderem auch der niedersächsische Umweltminister Stefan Wenzel teilnimmt. Die Freiburger Agentur Enerchange richtet die Tagung gemeinsam mit der Wirtschaftsfördergesellschaft hannoverimpuls und dem Geozentrum Hannover aus, das mit seinen drei Organisationen (Bundesanstalt für Geowissenschaften und Rohstoffe, Landesamt für Bergbau, Energie und Geologie und Leibniz-Institut für Angewandte Geophysik) aktiv an der Gestaltung des Tagungsprogramms beteiligt ist. Alle Informationen zum Programm und die Möglichkeit zur Online-Anmeldung finden Sie unter:
www.norddeutsche-geothermietagung.de
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Veranstalter Enerchange ist eine unabhängige Spezialagentur für PR, Veranstaltungen sowie Informations- und Beratungsdienstleistungen im Bereich Erneuerbare Energien und nachhaltige Energienutzung. Unser Leistungsspektrum umfasst die Recherche und das Publizieren von Fachinformationen, die Organisation von Veranstaltun- gen, die Presse- und Öffentlichkeitsarbeit sowie die Beratung von Unternehmen bei der Umsetzung von Erneuerbare-EnergieProjekten. Initiatoren der Norddeutschen Geothermietagung sind das Geozentrum Hannover mit seinen drei unten aufgeführten Instituten und hannoverimpuls. Im Frühjahr 2011 haben die Institutionen Enerchange mit der Durchführung der Veranstaltung betraut. Als Mitveranstalter unterstützen sie Enerchange bei der Programmgestaltung und Organisation der Tagung. hannoverimpuls ist die gemeinsame Wirtschaftsentwicklungsgesellschaft von Stadt und Region Hannover. Ziele des Unternehmens sind die Gründung, das Wachstum und die Ansiedlung von Unternehmen in der Region Hannover sowie die strategische Steuerung der Tochtergesellschaften für Marketing, Tourismus, Fonds und Internet. Die Bundesanstalt für Geowissenschaften und Rohstoffe (BGR) ist die zentrale geowissenschaftliche Beratungseinrichtung der Bundesregierung. Als geowissenschaftliches Kompetenzzentrum berät und informiert sie die Bundesregierung und die deutsche Wirtschaft in allen geowissenschaftlichen und rohstoffwirtschaftlichen Fragen. Das Landesamt für Bergbau, Energie und Geologie (LBEG) ist Bergbehörde für Niedersachsen, Bremen, Schleswig-Holstein und Hamburg sowie Geologischer Dienst für Niedersachsen. Zu den Kernaufgaben des LBEG gehören die Bergaufsicht in den Bereichen Rohstoffgewinnung, Rohstofftransport (Pipelines) und Energierohstoffspeicherung, die Beratung und Verfahrensbeteiligung z. B. in der Energiewirtschaft und die Bereitstellung von Geofachdaten. Das Leibniz-Institut für Angewandte Geophysik - LIAG ist eine eigenständige Forschungseinrichtung, die mit den Methoden der Angewandten Geophysik geowissenschaftliche Fragestellungen untersucht. Der Schwerpunkt der Arbeiten des LIAG liegt in der Erkundung des nutzbaren Untergrundes sowie in der Entwicklung von Mess- und Auswerteverfahren, die hierbei zum Einsatz kommen.
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Company-Presentation NEWS & REPORTS
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
• 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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Company-Presentation NEWS & REPORTS 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
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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Presentation NEUHEITEN of new & REPORTAGEN products
Mining Calculator: A Software for Mine Optimization Software characteristics • • • • • •
Individual equipment selection for loading and haulage Discontinuous and continuous haulage systems Equipment matching Economic analysis Ecological assessment (greenhouse gas emissions) Overall-comparison and rating of different bulk material handling systems as a basis for key decisions • Improvement of economic and ecological feasibility
Key applications • • • •
Feasibility studies for green and brown field projects Optimization of operating mines and earthmoving projects Evaluation of project development dynamics Education
• • • • •
Selection of loading and haulage systems Equipment matching Calculation of various cost types Determination of CO2-emissions Presentation of results by tables and diagrams
Key functions
Mining Technology Consulting Albrecht-von-Groddeck-Str. 3 38678 Clausthal-Zellerfeld | Germany XGraphic Ingenieurgesellschaft mbH Aretzstr. 9 52070 Aachen | Germany
Ausgabe 02 | 2013
Information and contact:
Internet: www.mining-calculator.com eMail: info@mining-calculator.com
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IMPRINT PUBLISHING COMPANY
AMS Online GmbH Diepenbenden 29 52076 Aachen | Germany eMail: redaktion@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
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BANK CONNECTION
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GRAPHICAL DESIGN
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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
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