est of ermany mining equipment 2017 · takraf gmbh torgauer straße 336 04347 leipzig, germany...

BEST OF GERMANY

2017

Mining Equipment

and Technology

A supplement to E&MJ, Coal Age, Equipo Minero,

E&MJ/Coal Age Russia, E&MJ/Coal Age China,

E&MJ/Coal Age India and The ASIA Miner

In cooperation with VDMA

Mining

TAKRAF GmbHTorgauer Straße 33604347 Leipzig, [email protected]

TAKRAF is a key equipment and systems partner

for open pit mining and bulk handling, having

provided hundreds of complete systems, as well

as individual machines, to clients all over the

world. Based upon more than a century of

experience and know-how, the product range

stretches from overburden removal, raw material

extraction, conveying, processing, comminution,

homogenizing, blending and storage to onward

transport or shipment.

TAKRAF has committed to both environmental

and social sustainability in their business

interactions and has adopted a Zero harm

approach to safety under the SAFETY FIRST

promise of the Tenova Group.

Tenova, a Techint Group company, is a worldwide partner

for innovative, reliable and sustainable solutions in the

mining and metals industries. www.tenova.com

This is what our engineers say:

«We continue to innovate and our

conveying solutions often push the

boundaries in terms of what’s been done

before across such areas as installed

drive power, direct-drive technology,

distance between pulley centers,

belt quality, overall distance

and capacity.

My engineering team

enjoys a challenge!»

mailto:[email protected]

http://www.takraf.com

http://www.tenova.com

VDMA 12017 • VDMA MINING SUPPLEMENT

Foreword: Committed to the Mining SphereWelcome to the 2017 edition of the Best of Germany, which highlights the expertise of the companies

that provide equipment and services to the mining and mineral processing industries worldwide. We

believe the mining industry will soon experience a positive change after several years of austerity.

The member companies of the Mining Equipment Association of the German Engineering

Federation (VDMA Mining) have had to apply similar conservative measures to cope during this period

as well, and they are looking forward to an improvement in the mining business. Most VDMA Mining

members are diversifi ed, privately held companies that relied on their fi nancial resources to maintain

the needed skill sets. And, today, we can say with pride that the member companies have managed

to retain the craftsman and engineering expertise to produce high-quality equipment.

It’s true. We have competitors who offer less expensive equipment and services. This approach

lessens the immediate capital outlay. Mining projects, however, are designed to operate 15 years

or more and, when one considers the total cost of ownership, it’s diffi cult to compete with German

craftsmanship.

One of the recurring themes in the Best of Germany 2017 is the use of technology to enhance

operations. The dip in new equipment sales allowed VDMA Mining members to focus their attention

on potential effi ciency improvements for mining and milling operations and to possibly rethink future

production strategies.

The VDMA Mining members did not give up on the global mining business and they are now better

prepared to deliver when the industry recovers once again. Committed to the mining sphere, Germany

remains a step ahead. This edition of the Best of Germany highlights the direction VDMA Mining

members have taken, and we hope that you fi nd value in this publication.

Glückauf!

Dr. Michael Schulte Strathaus

Chairman

VDMA Mining

Table of Contents:

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

VDMA Mining Looks Past the Recession ............................................................................................ 4

Surface Mining: Increasing Reliability and Productivity .................................................................... 6

Health and Safety: A Safe Haven Underground................................................................................ 15

Underground Mining: Where Power Meets Safety ............................................................................. 18

Material Handling: Moving Minerals................................................................................................ 25

Mineral Processing: Recovering More With Less .............................................................................. 32

Innovations: Renewable Energy Reduces Mining Costs ................................................................... 34

Vendor Matrix and Buyers Guide ...................................................................................................... 38

A Special Supplement to:

Engineering & Mining Journal (E&MJ)

and Coal Age

Produced by:

Mining Media International Inc.

11655 Central Parkway, Suite 306

Jacksonville, FL, 32224, USA

Tel: +1-904-721-2925

Fax: +1-904-721-2930

www.mining-media.com

Copyright 2017 Mining Media Int’l, Inc.

Sponsor:

German Engineering Federation Verband

Deutscher Maschinen und Anlagenbau

(VDMA) e.V.

Lyoner Str. 18, D-60528 Frankfurt/Main

Tel: +49-6966-031262

Fax: +49-6966-032262

www.vdma.org

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

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

EQUIPO | INGENIERÍA | TECNOLOGÍA

Published by Mining

Media International

in cooperation with

VDMA Mining

http://www.mining-media.com

http://www.vdma.org


VDMA 2 VDMA MINING SUPPLEMENT • 2017

Joachim Schmid Managing Director

Phone: + 49 69 6603-1261

Fax: + 49 69 6603-2261

Email: [email protected]

Helmut Schgeiner Director

Technology, standardization and research,

markets Europe, Africa, USA and Canada

Phone: + 49 69 6603-1680

Fax: + 49 69 6603-2680


Christoph Danner Manager Markets

Latin America

Phone: + 49 69 6603-1254

Fax: + 49 69 6603-2254


Alexandra Landgraf Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Rajesh Nath Chief Representative

VDMA Representative Offi ce India

Phone: + 91 33 40602364

Fax: +91 33 23 21 70 73


Sven Flasshoff Chief Representative

VDMA Representative Offi ce Russia

Phone: + 7 499 41803-71

Fax: + 7 499 41803-72

Email: sven.fl [email protected]

Your Contacts in theMining Equipment Association

Klaus Stöckmann Deputy Managing Director

Economy and statistics, trade fairs,

markets Asia and Australia

Phone: + 49 69 6603-1270

Fax: + 49 69 6603-2270


Monika Bind Manager Markets

CIS and Russia

Phone: + 49 69 6603-1262

Fax: + 49 69 6603-2262


Jörn LehmannManager Standardization

Phone: + 49 69 6603-1134

Fax: + 49 69 6603-2134


Yvonne Golle Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Thomas JunqueiraAyres Ulbrich Chief Representative

VDMA Representative Offi ce Brazil

Phone: + 55 11 430580-42/-43

Fax: +55 11 3078 4335


Claudia BarkowskyChief Representative

VDMA Representative Offi ce China - Beijing

Phone: +86 10 87 73 02 12-8 08

Fax: +86 10 87 73 02 09


Joachim Schmid Managing Director

Phone: + 49 69 6603-1261

Fax: + 49 69 6603-2261


Helmut Schgeiner Director

Technology, standardization and research,

markets Europe, Africa, USA and Canada

Phone: + 49 69 6603-1680

Fax: + 49 69 6603-2680


Christoph Danner Manager Markets

Latin America

Phone: + 49 69 6603-1254

Fax: + 49 69 6603-2254


Alexandra Landgraf Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Rajesh Nath Chief Representative

VDMA Representative Offi ce India

Phone: + 91 33 40602364

Fax: +91 33 23 21 70 73


Sven Flasshoff Chief Representative

VDMA Representative Offi ce Russia

Phone: + 7 499 41803-71

Fax: + 7 499 41803-72

Email: sven.fl [email protected]

Klaus Stöckmann Deputy Managing Director

Economy and statistics, trade fairs,

markets Asia and Australia

Phone: + 49 69 6603-1270

Fax: + 49 69 6603-2270


Monika Bind Manager Markets

CIS and Russia

Phone: + 49 69 6603-1262

Fax: + 49 69 6603-2262


Jörn LehmannManager Standardization

Phone: + 49 69 6603-1134

Fax: + 49 69 6603-2134


Yvonne Golle Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Thomas JunqueiraAyres Ulbrich Chief Representative

VDMA Representative Offi ce Brazil

Phone: + 55 11 430580-42/-43

Fax: +55 11 3078 4335


Claudia BarkowskyChief Representative

VDMA Representative Offi ce China - Beijing

Phone: +86 10 87 73 02 12-8 08

Fax: +86 10 87 73 02 09














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Last year was a difficult year for the mining business and the com-

panies that serve it. Coal production and consumption, which rep-

resents the largest investment by commodity, declined significantly

in both China and the U.S. While the situation for metal/nonmetal

mining was not nearly as stark, many of the mining companies took

a conservative approach to capital spending, opting for efficiency

improvements and brownfield expansions rather than greenfield

construction and purchasing new equipment.

Following a decline in turnover of approximately 21%, down

to EUR 2.8 billion in 2016, German equipment suppliers foresee

stabilization in 2017 and they are preparing for improved business

in 2018.

Speaking at its annual meeting at the Zollverein coal mine in

Essen, Germany, during November, Chairman of the Mining Equip-

ment Association of the German Engineering Federation (VDMA

Mining) Dr. Michael Schulte Strathaus said he believes that rising

raw material prices and the mining industry’s willingness to invest

again will bring an end to the days of two-figure declines in turn-

over. “In the third quarter of this year, mining equipment manufac-

turers registered a 12% increase in incoming orders in comparison

to the same period the previous year,” Schulte Strathaus said. “The

respective index rose over the same period from 61 to 80 points.

However, the period from the receipt of an order to its settlement can

run up to 15 months. The renewed increase in turnover can therefore

be anticipated in early 2018.”

Statistics indicate that the industry has reached the bottom of

the cycle. Mining companies are realizing profits again and soon

they will invest in more machinery and equipment.

Managing Through the TroughRegarding the significant drop in revenues, comparing the first nine

months of 2016 against 2015, revenues in Germany fell 36% to

around 200 million euros and 21% for exports to just under 2.6

billion euros. “Growth rates of more than 10%, as we had in 2012,

will hardly be possible in the foreseeable future,” Schulte Strathaus

said. “We will more likely be talking about 2%-4%, but we expect

the mining market to stabilize this year and begin to grow again.”

Despite this not exactly simple situation, the companies have

succeeded in maintaining a steady workforce of 12,000 employees.

“Our member companies have, by dint of strenuous efforts, kept

their permanent staff,” Schulte Strathaus said.

VDMA Mining’s domestic business continues to decline. Schulte

Strathaus ascribes the domestic decline to missing contracts in the

hard coal industry. The last German hard coal mine will close in

2018. Brown coal, potash and salt and stone are still mined.

“Germany operates a small-scale, incalculable energy policy

that is not always understandable in terms of energy economics,”

Schulte Strathaus said. “Although no substitute is available, the en-

ergy supply guaranteed by brown coal is undermined. Incomprehen-

sible decisions on energy policy are made based on national environ-

mental requirements that go well beyond European or international

agreements. What the politicians lack is a reasonable plan and it is

affecting manufacturing in Germany with higher electrical costs.”

Healthy Prospects WorldwideThe largest export market for German mining equipment man-

ufacturers is the European Union, which represents 20% of the

mining-related exports. In the past, this fact has shifted into the

background due to the large single markets in China, Russia and

VDMA Mining Looks Past

the Recession


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the U.S., Schulte Strathaus explained. Business is robust with the

United Kingdom, Italy and France. Demand exists in particular for

machinery used in tunnel construction. At a minimum, similar turn-

over is assumed for the coming year.

Schulte Strathaus also reported robust business with Turkey. In

terms of raw materials, the country is increasingly investing in self-

sufficiency to reinforce its economic foundations and to reduce its de-

pendence on imports from abroad. This is relevant with respect to en-

ergy supply from coal as well as to manufacturing industrial metals.

The second most important turnover region, with a share of

11%, is Africa, Northern Africa in particular. Since 2014, VDMA

Mining exports to this region have almost tripled. The largest mar-

kets are Egypt and Algeria. Sales are based first and foremost on

machinery and plants related to infrastructure projects. “It’s not

about machines and equipment for the mining industry, but mainly

for infrastructure projects, such as the four road and railway tunnels

underneath the new Suez Canal,” Schulte Strathaus said. “Africa

is developing further and further, not least with massive financial

and human support for China. For the coming year, however, we are

expecting further moderate increases in exports.”

The third largest market is the U.S. Approximately 10% of ex-

ports make their way to the U.S. Sales are based mainly on pro-

cessing technology and excavating machinery. Schulte Strathaus

expresses doubt as to whether mines will continue to close and coal

mining will continuously be reduced under the new administration.

“President Trump has not only promised to preserve jobs in this sec-

tor, but to even create new ones,” Schulte Strathaus said, and VDMA

Mining assumes that its share of U.S. exports will grow in 2017.

Latin America is VDMA Mining’s fourth-largest export des-

tination, accounting for about 7% of total exports. These mining

operations have seen profits recover along with improving metals

prices. “Higher liquidity and the prospect of further profits does not

necessarily lead to more investment,” Schulte Strathaus said. “Po-

litical stability is important. This can be seen especially in Brazil

and Venezuela, when compared to Peru, Mexico and Chile.”

In China and Russia, which ranked 6% and 5%, respectively, for

VDMA Mining, the situation is quite different. German-Russian rela-

tions in the mining sector can still be described as good and intact.

After the imposition of sanctions, many of VDMA Mining’s customers

sought equipment and services from China. “That has not worked

out as promised,” Schulte Strathaus said. “For a number of compa-

nies, Russia continues to be of great importance as a sales market.”

This is also true for China, he explained. “There is, however, con-

siderable uncertainty among our member companies about how the

country will evolve,” Schulte Strathaus said. “China must balance

increased environmental protection and rising energy demand. The

views of VDMA Mining is divided. On the one hand, they expect it to be

better and on the other, they expect business to get worse. The latter

sentiments mostly apply to underground mining, especially coal.” It’s

different for open-cast mining. Here, good orders are still expected by

VDMA Mining, but overall they expect a slight decrease in exports.

Schulte Strathaus sees the increasing diversification among

companies represented by VDMA Mining as a positive step. New

products are increasingly brought into the market and new export

regions are also being established. Meanwhile, virtually all the

renowned manufacturers that sold exclusively to coal are offer-

ing machinery for hard rock mining. This is resonating positively

among purchasers on the whole. Schulte Strathaus announced a

Europe-wide networking of companies. Thus, it should become pos-

sible among other things to bring new products into the market to-

gether, with greater impact.

http://www.beumergroup.com


By any standard, the machines employed by modern open-pit mines

to extract, load and haul rock are some of the largest pieces of

equipment on Earth. Moreover, these machines are expected to per-

form at the same optimum level as any other operation. Reliability

is extra important. Having a bucketwheel, a dragline, a shovel or

a couple of haul trucks down for even a shift can be an incredibly

costly proposition.

These large pieces of equipment also rely on a host of support

equipment. With conventional mining processes, dozers clear the

bench for the shovels, while front-end loaders keep the loading area

clean, reducing tire damage on the trucks. Sometimes those same

loaders can be the primary loading tool.

Engineers today are looking beyond conventional load-and-haul

strategies to more continuous material handling methods, such as

in-pit crushing and conveying (IPCC). These systems could also be

used in connection with continuous mining systems, such as sur-

face miners and bucketwheel excavators.

The theme of this edition of the Best of Germany is “Commit-

ment to the Mining Space,” and Liebherr Mining identifies strongly

with that. The company is privately held with a long-term vision and

they support the mining industry during good times and the not so

good times, albeit with a bit more diversification than others.

For the open-pit mining sector, Liebherr supplies equipment for

loading, hauling and pushing rock. This type of equipment requires

an extended lead time to manufacture. Similar to a mining opera-

tion, an equipment manufacturer cannot simply turn the truck or

excavator factory on and off at the flip of a switch. For the last

few years, Liebherr managed to keep most of their people in place

and they also invested in their manufacturing facilities and a few

new service and support facilities in mining districts. When miners

return to the market for new equipment, they will be prepared.

In the meantime, the company has also been working to improve

its service and customer support strategies. Liebherr continues to

integrate vertically. A prime example is the expanded use of the Li-

ebherr electronic (or Litronic) system, which integrates the AC drives

with the drivetrain in the case of the haul truck. Last year, they also

unveiled the new V-diesel engine D9812, which has a power rating

up to 2,700 hp (2,015 kW). “The real message here is that we con-

tinue to invest in the development of our own components,” said Dr.

Joerg Lukowski, executive vice president, mining equipment, for Li-

ebherr. “Next door to the excavator factory in Colmar, we have built a

high-horsepower engine factory. Since we have started to introduce

the Liebherr engines in our 100-ton diggers, we have more and more

customers already asking for Liebherr engines in the larger diggers

and in the trucks. People are excited about them, but we need to

prove the engines are reliable and fuel efficient.”

Liebherr invested in a new service center in Adelaide, an iron

ore support center in Newman, a parts facility in Perth, a new ser-

vice center in Siberia and a new facility for the oils sands in Fort

Mackay, Alberta. “We have target markets and we continuously

invest in those regions,” Lukowski said. “Liebherr Australia for

example is already well-established throughout the continent, but

still we continue to invest. We needed a remanufacturing facili-

ty in Adelaide and we decided to build one. In the Americas, we

do not have as great a presence as we would like and so we put

focus here to expand our project base. If we have an individual

project somewhere that needs support, we will make an on-site

investment with a repair facility and spare parts. If more projects

appear nearby, we may decide to invest in a full-service facility. In

markets where we have critical mass, we usually then finally build

a Liebherr-owned company.”

Surface Mining: Increasing

Reliability and Productivity Ultimately, the lowest cost per ton prevails

Liebherr’s T 284 haul truck has a 400-ton payload, the highest in the industry.

Ground engaging tools (GET) has been a very successful aftermarket item

for Liebherr.

Liebherr T 264 – Technology for Your Excellence

Superior speed on grade through highly efficient power train

Low fuel burn due to efficient Litronic Plus drive system

Class-leading fuel economy extends operation

Simplified design for reduced maintenance time and increased service interval

OEM quality engineered and built components deliver maximum uptime

Experience the Progress.

Liebherr-Mining Equipment Colmar SAS49 rue Frédéric Hartmann - CS 5003868025 Colmar CedexPhone: +33 369 49 20 00E-mail : [email protected]/LiebherrMiningwww.liebherr.com


http://www.facebook.com/LiebherrMining

http://www.liebherr.com


Liebherr introduced the R 9200 hydraulic excavator to the North

American mining market at MINExpo 2016. Equipped with an ad-

vanced package of ground engaging tools (GET), the 9200 has a

16.3-yd3 (12.5-m3) bucket capacity, which offers the biggest pay-

load in its class. This new 200-ton machine is designed to match

mining trucks with payloads of up to 140 tons. “The GET has been

a very successful aftermarket item for us and it has been received

well by many customers,” Lukowski said.

Liebherr has also added high-performance kits for its hydrau-

lic excavators. Lukowski explained: “We have also used a targeted

approach to reduce the weight of the attachment while maintaining

the lifetime of the components. We have seen as much as a 13%

gain on the large mining excavators.”

The Litronic systems for the haul trucks has been developed

through a similar evolutionary process that started with the 282

and then became available with the 284 and the 236. “It’s different

systems working together, it’s not just one element or one part in

a haul truck,” Lukowski said. “It’s a combination of several com-

ponents that increase productivity and efficiency. We have demon-

strated it on the 284 where the Litronic Plus AC drive system also

includes the drivetrain.”

The T 284 haul truck offers the highest payload in the industry

(400 tons) and with intelligently designed systems and components,

it could serve as a platform for future advances in mining truck

technology. Buyers can select the engine that will allow the truck to

meet productivity targets while minimizing fuel consumption.

Liebherr-Mining Equipment has developed an advanced soft-

ware tool to improve troubleshooting efficiency, the Troubleshoot

Advisor. It detects the cause of breakdowns for mining trucks and

excavators and proposes a procedure based on the results of diag-

nostic tests. “This software tool is currently supporting field service

teams in more than 20 countries, and they have been able to reduce

fault finding and trouble-shooting by a factor of five,” Lukowski said.

Lukowski expects the cost per ton to remain a hot topic. “Some

purchasing managers tend to focus on initial capital costs rather

than the cost per ton,” Lukowski said. “At the end of the day, what

counts is the lifetime equipment costs per ton. And that is where

uptime and high productivity of our machines also plays a major

role.” Looking toward the future, he sees smaller machines doing

the same work as larger machines, where a 400-ton machine is

producing as much as a 600-ton machine today.

Digital Asset CareSince it was established in 2015, RWE Technology International

(RWE TI) has developed into a leading independent consulting and

engineering company, providing services to various energy markets

including mining, thermal generation, renewables and grids. The

company provides services to the global mining industry with a spe-

cial emphasis on continuous open-cast mining and in-pit crushing

and conveying (IPCC) Technology.

“Our mining expertise covers minerals and solid fuels and

spans exploration, development, operations and rehabilitation,”

Over a period of 6 days and five nights, a team of 24 technicians, electricians and supervisors worked around the clock to complete the R 996 B engine module

changeover at Yancoal’s Moorlarben site.


RWE Technology International

PUSHING THE LIMITS

EXPANDING YOUR PROFITRWE Technology International is the world’s leading consultant for technical

and operational expertise in open-cast continuous mining systems. RWE TI’s

expertise is based on its experience in operating 230 km of the largest and

fully shiftable conveyors with capacities of up to 37,500 t/h.

T +49 201 12-28742

E [email protected]

I www.rweti.com

said Arie-Johann Heiertz, sales manager, mining, RWE TI. “We draw

on the extensive operation and engineering knowledge as well as the

practical experience of our mother company RWE.” RWE operates

five coal operations, mining 120 million metric tons (mt) of lignite

and moving 900 million mt of overburden. In total, the company

operates and maintains more than 230 km of conveyor systems.

Even though RWE’s equipment mines coal in a highly energy-ef-

ficient and cost-effective manner, it is still susceptible to heavy

wear and tear. The mining equipment operates 24/7, deals with

abrasive materials and is exposed to all kinds of weather. It is con-

tinually maintained to ensure minimal downtime.

More recently, RWE collaborated with IBM to develop an

award-winning analytics driven app to ensure that the maintenance

procedures of complex, large equipment and assets are adequately

performed. Asset Care will be the first in a suite of apps that RWE

and IBM will jointly develop and deploy to RWE’s field forces using

iPads to improve maintenance efficiency for mining operations.

“Efficiency is a key interest when it comes to operation and

maintenance of our heavy equipment,” Heiertz said. “The new tool

gives RWE’s employees real-time access to constantly monitor the

equipment and to forecast situations more precisely when a ma-

chine might be running into an unplanned outage.”

The Asset Care App running on an iPad mini will actively support

RWE’s maintenance engineers, technicians and craftsmen by pro-

posing the specific maintenance tasks previously determined to pre-

vent outage or damage. Currently, all expert crews must complete

forms to initiate and keep record of the maintenance jobs required.

The handwritten information is then transcribed to a traditional

plant maintenance software system.

“Asset Care eliminates this manual process by streamlining

tasks and allowing field workers to instantly capture repair informa-

tion in the app, including image and video files, so they can easily

identify equipment issues and complete tasks more efficiently and

safely,” Heiertz said. Field technicians are equipped with mobile ac-

cess to real-time updates of manuals, maintenance and operational

history, and also GPS-based location systems for monitoring and

The Asset Care App running on an iPad mini supports maintenance engineers.


http://www.rweti.com


tracking of equipment and field workers, resulting in a reduction in

equipment downtime and cost of maintenance.

Both IBM and RWE have identified that Asset Care is an in-

dustry solution that could support the transformation of how main-

tenance operations are delivered in industries with large and com-

plex assets.

Maximizing Coal RecoveryMost coal operations measure the particle size distribution (PSD)

of the plant feed to determine the suitability of the feed for their

process. Fine coal can present a problem and understanding the

origin is helpful, but few mines measure the PSD. Comparing that

information with the plant feed data, the mine could optimize the

processes in between the face and the plant to reduce the fines

in the run-of-mine (ROM) coal, which could generate savings and

benefits, such as:

• Reducing the costs associated with fines recovery;

• Decreasing the load on the tailings storage facility;

• Complying with customer specifications;

• Reducing coal dust and its associated problems; and

• Decreasing the moisture the fines retain.

Coal breakage occurs throughout the production process and

generally the amount of breakage behavior depends on the ge-

ology and how the coal is mined and handled. Wirtgen recently

performed several large-scale field tests on material degradation

and found that surface miners offer surprising advantages when it

comes to coal fines generation.

A Wirtgen surface miner is a crawler-mounted mining machine

with a rotating cutting drum and a slewing system for loading

trucks or windrowing product. The cutter drum is located near the

machine’s center of gravity, which transforms the machine’s full

weight into rock penetrating force. The machine can cut layer by in-

dividual layer. The cutting depth can vary with the seam thickness.

Even seams as thin as 10 cm can be mined and precisely separated

from interburden. This is a selective, cost-effective form of surface

mining that does not involve drilling and blasting.

In recent years, Wirtgen has conducted several large-scale

field tests on PSD and material degradation. Coal and sedimentary

ore from eight different pits were analyzed to obtain PSD. Almost

8,000 metric tons (mt) of material were screened to compare the

material produced by surface miners and conventional mining

methods.

In one coal mine, Wirtgen surface miners operate alongside doz-

ers that employ the conventional rip-and-stack method. In view of

the current coal prices, the mine was optimizing every step of the

operation. This included optimizing the process for target size ma-

terial, enabling most of the material to be processed in the cheaper

coarse circuit of the processing plant. They also were keen on reduc-

ing crushing costs.

The surface miner delivered coal with a lower percentage of

fines and more target size material than the conventional dozer rip-

and-stack method. In fact, out of the 1,500 mt/h of coal delivered

from the dozer to the processing plant, 225 tph are fines (less than

2 mm). With the surface miner, the fines amounted to 185 mt/h,

22% less coal was washed in the fines circuit. Looking at the ultra

fine material (less than 1 mm), the plant sees 33% less of that size

fraction when working with surface miner coal.

The surface miner delivered more than 70% target size coal (2

mm-40 mm), while the dozer ranges at less than 58%. Additionally,

savings are generated in the crushing stage: only 17% of the mate-

rial coming from the surface miner needs to be crushed, as opposed

to more than 26% when processing ripped coal.

Another trial location was a sedimentary ore deposit that is

mined using surface miners vs. a conventional drill-and-blast

method. There, the surface miner continually produced feed materi-

al with a minus 1-mm size fraction as low as 15% to the processing

plant. The normal plant feed (includes material of drill-and-blast

and surface miner operation) contained 25% and more fines less

than 1 mm.

Re-handling contributes significantly to the material degra-

dation occurring during the mining process. Simulating the re-

handling of material, Wirtgen conducted a study to establish the

Wirtgen surface miners — here the 4200 SM — cut and crush the rock with a special cutting drum and load it onto dumpers in a single pass via conveyor

system. Wirtgen is the only manufacturer that can offer a performance range up to 3,000 t/h with direct loading by conveyor belt.

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amount of material degradation that does occur. For simulation

purposes, 80 mt of material were loaded by a wheel loader and run

through a screening plant several times. With every throughput,

the amount of fine material increased significantly. During five test

cycles for coal, the amount of minus 4-mm coal increased from

19% to 26%, representing an increase of 34%. A similar result

was found with sedimentary ore: the fine fraction increased by 24%

during five test cycles.

None of the steps in this re-handling simulation (loading,

transport to the screen deck, sizing on the screen deck itself) in-

volves the high material stress levels that would be induced, for

example, by a dozer moving on stockpiled material. Nevertheless,

significant material degradation was measured during the simu-

lation. One can assume that the material degradation that takes

place during stockpiling results in an even higher increase of the

fine fractions.

Keeping in mind that even this kind of “soft” re-handling

causes significant material degradation and that a lot of re-han-

dling steps occur all along the mining process, it is important to

minimize the number of re-handling steps. What is more, every

re-handling step itself results in additional costs. This is where

Wirtgen surface miners offer a twofold advantage: Material mined

with a surface miner has not been blasted, but cut out of the

ground by the rotating cutting drum, thus the level of fines is

already low. But as the material is loaded straight onto a truck,

re-handling is kept to a minimum and thus the level of fines stays

as low as possible.

Looking at the complete mining operation, using a surface min-

er simplifies mining operation and reduces the number of process

steps, resulting in immediate cost savings.

Direct Conveyor Drives Offer High AvailabilityDeclining ore grades, leading to increased material transport and

plant throughput requirements, is one of the major challenges in

the current mining environment. With direct conveyor drive systems,

mining operators can overcome the mechanical limits of conven-

tional drive systems, and benefit from economies of scale — as

demonstrated in several projects in South America.

A direct conveyor drive system comprises a low-speed syn-

chronous motor, a cycloconverter or voltage source converter, drive

control, power distribution, an E-House and a cooling system. Elim-

inating various components of the drive train reduces maintenance

costs and spare part inventories, and allows the system to offer a

uniquely high degree of availability.

Even in challenging applications, direct conveyor drives

can achieve a benchmark availability of more than 99% — as

confirmed by real-world data from the Antapaccay mine in Peru.

There, the belt system transports approximately 5,260 metric

tons per hour (mt/h) of ore from the mine to the processing

plant over a distance of 6.5 km. The Siemens drive system for

the belt conveyor consists of two low-speed synchronous motors,

each with a power rating of 3,800 kW, and the associated Sinam-

ics SL150 cycloconverters, E-House cooling system and convertor

transformers.

The 2.5-km overload conveyor system at the Las Bambas copper mine in Peru uses a drive system developed by Siemens that consists of two low-speed

synchronous motors with a total power of 4,400 kW.


In 2015, Siemens commissioned direct conveyor drive systems

for two additional copper mines. One was for one of the largest cop-

per mines in the world, which is located in Chile (5 x 5,000 kW).

For the overland conveyor supplied by thyssenkrupp with a length

of more than 10 km, Siemens supplied five direct-drive systems

(for a total of four conveyors) with the largest conveyor motors pres-

ently in operation.

The overland conveyors at Las Bambas copper mine in Peru

were designed and supplied by thyssenkrupp and have been in

operation since the fall of 2015. Each of the two overland con-

veyors is approximately 2.5 km long with a lift of almost 300 m

and transports ore from the mine to the processing plant. The belts

are 1,830 mm wide, travel at 6.5 m per second, and are designed

to transport approximately 9,400 mt/h. The stockpile at the end

of the conveyor system is more than 50 m high and can supply

the processing plant with up to three days’ worth of copper ore

for processing. The drive system for each of the two overland

conveyors comprises two low-speed synchronous motors — each

with a total power of 4,400 kW — and the associated Sinamics

SL150 cycloconverters.

The overland conveyors at Las Bambas were commissioned

very quickly and the conveyor system is now in operation. “The

project has been very successful and we are running the conveyors

at nominal capacity with only a very few open issues. The gear-

less drives are beneficial from a service point of view, given that

there are no motor bearings or gearboxes, which simplifies ongoing

maintenance requirements,” said Timothy Mess, project director

for thyssenkrupp.

Peter Mizera, MMG’s general manager for Las Bambas project

delivery, shared a positive view of the project outcome. “Las Bam-

bas has been a great success, and Siemens was a large contribu-

tor to this outcome,” Mizera said. “Siemens provided solid support

during construction, precommissioning, and commissioning, and

as a result, we were able to complete the overland conveyor com-

missioning very quickly — in just under two months. This was a

fantastic achievement.”

Following Las Bambas, Siemens recently supplied the world’s

highest-powered direct conveyor drive system to the Cuajone mine

in Peru. The modernization project will entail the installation of a

new gyratory crushing and conveyor system from thyssenkrupp by

2016 (See Material Handling, p. 25). Siemens proposed an Integrat-

ed Drive System with direct conveyor drives to power this conveyor

system, which has a total power output of 12,000 kW.

The conveyor belt system comprises three individual sections

that are equipped with a total of five Integrated Drive Systems.

For the largest of the belt sections, Siemens is supplying two drive

systems with an output of 6,000 kW each, comprising a low-speed

synchronous motor and a Sinamics SL150 cycloconverter. The two

smaller feed and discharge belts will be driven by two 500-kW

low-voltage motors powered from Sinamics S150 converters with

regenerative feedback capability and one 1,200-kW medium-volt-

age motor. The converters and motors as well as the gearboxes and

couplings for these drives are all supplied by Siemens.

The automation components and the drive and power distribu-

tion technology are provided in modular electrical rooms. Over the

years, Siemens has improved and optimized the cooling system, the

modular design of these electrical rooms, the power distribution,

and the automation and drive control so that they perfectly address

the mining industry’s specific requirements.

At Cuajone, Siemens will continue the company’s impressive

track record of successful projects in South America — and rein-

force its position as one of the leading suppliers of electrical and

automation systems for the global mining industry.

Fuel Filtration SystemTo ensure reliable performance for Series 4000 mining engines

operating in harsh conditions where fuel standards are difficult

to uphold, MTU engineers designed a new upgrade to the fuel fil-

tration system. The goal was to improve the system’s ability to

remove particle contaminants in the fuel before they reach the

injection system.

The first aspect of the upgrade involves replacing the filter el-

ements within the primary and secondary filtration unit with new

MTU high-efficiency filtration elements. This ensures that filtered

fuel meets the standards required by the Series 4000’s common rail

injection system. To achieve such high efficiency, the filter elements

are embedded with extremely fine glass fibers, which enable a very

high separation with maximum dirt holding capacity. The MTU High

Performance Fuel Filtration kit includes two primary and two sec-

ondary filter elements.

The new filters are designed to have similar change-out in-

tervals as the original filters. In extreme conditions, a significant

increase in filtration is often accompanied by a reduction in filter

lifetime within the primary and/or prefiltration system. To compen-

sate for these reductions, MTU developed additional upgrades for

both pre- and primary filtration units.

To test the MTU Fuel Filtration Upgrade Kit, prototypes were in-

stalled in 20-V 4000 MTU engines in 360-ton Liebherr T-282 mine

haul trucks, at three mine sites: North Antelope Rochelle mine (Wy-

oming, USA), Kaltim Prima Coal (Indonesia) and Mount Arthur Coal

(Australia). As a benchmark, a standard fuel filter was installed in

a similar truck at each site. Both trucks at each site endured a full

7,000 hours of operation under the same conditions.

After the testing period, all the injectors were inspected and

the results showed the new filtration offered significant improve-

ments. Injectors showed less wear at 7,000 hours than at 3,000

hours with the original filtration system. Most cases showed a

50% to 60% improvement in longevity. In some cases, injector life

was doubled.

Removing the necessity of an injector change just once over

the lifetime of an engine offers significant savings. In harsh con-

ditions, several changes can be avoided. With the high-efficiency

fuel filtration upgrade kit, reaching the expected life of the injector

components is possible, even when fuel quality standards are dif-

ficult or impossible to meet. In addition, fuel efficiency is improved

and the risks of engine damage by worn injectors and other com-

ponents are minimized.

One of the first mine operations to choose the new upgrade

kit was the Radomiro Tomic copper mine in Chile, one of the most

challenging sites in the world to meet stringent fuel standards. Lo-

cated 9,800 ft above sea level, dust is ever-present and fuel must

go through multiple transfers on its long trek to the site. Previously,

injectors achieved nearly 4,000 hours of life. With the installation of

the new upgrade, they are now achieving more than 8,000 hours.

Unexpected equipment downtime has been dramatically re-

duced as well. In addition to solving the problems associated with

fuel contamination, the upgrade kit enabled the mine to keep fol-

lowing the same exchange intervals as the previous series produc-

tion filters. Many haul truck engines at Radomiro Tomic work more

than 20 hours a day. Every time equipment is down, it costs the

mine operator money. Reducing maintenance time pays off expo-

nentially over time, and across many vehicles in the fleet.


The new Mine Refuge Chamber (MRC) 5000 attracted a lot of atten-

tion at MINExpo last year. A total life support system, this cost-ef-

fective chamber was completely designed by Dräger — from the

seal-welded steel structure and redundant air supply system, to the

soda lime cartridges and gas detection devices.

“Because we design and build most of the individual compo-

nents, we created a well-integrated, technically advanced life sup-

port system,” said Brad Rekuc, sales manager, mining, for Dräger.

“The MRC can be leased or purchased, and is totally supported by

Dräger Service with local maintenance and repair to ensure that the

chamber is always operational.” Because every mine is different,

Dräger also offers engineered chambers that are designed and built

to customer-specific requirements.

Several systems work together in the chamber to provide a safe

breathing environment. The chamber can be connected to an exter-

nal air supply. Oils, water and small particles are filtered from the

air. A constant positive pressure of between 150 and 200 Pa in the

chamber prevents contaminated air from entering the main room.

This safety feature is automatically sustained and controlled by the

Dräger Breathing Protection Unit (BPU).

Armed with positive pressure and a reliable air supply system, a

gas-tight door prevents contaminated air from entering the cham-

ber. The Dräger Airlock has an air purging system that dilutes any

contaminated air that enters. This allows miners to enter and exit

the chamber multiple times, while minimizing the risk of noxious

gas and smoke entering the chamber.

Dräger gas detection systems continually monitor the air inside

the chamber, which allows miners to adjust the system depending

on the values for carbon dioxide (CO2) and oxygen (O

2). The chamber

is a self-sufficient underground emergency chamber, meaning that

it does not depend on external air or power supplies to keep miners

safe. The air inside the chamber is regenerated by the CO2 scrubbing

process in the breathing air regeneration system.

CO2 is removed (scrubbed) from the interior air by easy-to-use

Drägersorb soda lime cartridges, which eliminate direct contact

with soda lime dust. Miners simply remove the caps, break the foil

seals and insert the cartridges into the top of the BPU. This pour-

free scenario eliminates the possibility of soda lime dust exposure in

a small space. The BPU has a dedicated battery backup system, and

each fan works independently and can be adjusted for the number

of occupants.

In self-sufficient operations, high-pressure cylinders replenish

O2 levels. Dräger’s proprietary gas detection equipment continuously

monitors the internal atmosphere for the presence of CO2 and CO,

as well as O2 levels. If gas concentrations fall outside preset limits,

audible and visual alarms warn the miners so they can adjust sys-

tems and maintain a safe atmosphere. An air conditioning system

keeps the chamber’s interior temperature and humidity at comfort-

able levels. In addition, a fixed external gas monitoring system that

measures the CO and O2 concentrations outside of the chamber and

displays results inside the chamber can be installed as an option.

The electrical system for the MRC 5000 includes batteries for all

electrical functions, the air conditioning system, and green and red

external status lights. Together with the inverter/charger system,

battery backup ensures continuous power for up to a minimum of 24

hours (extended times are optional).

With a history that dates back to 1889, Dräger is an internation-

al leader in the fields of medical and safety technology. The com-

Health and Safety: A Safe Haven

Underground

The MRC 5000 is a self-sufficient underground emergency chamber.


pany’s portfolio of mine safety products including gas detection

solutions, personal protective gear, innovative firefighting equip-

ment, and thermal imaging cameras.

Flameproof Technology Improves Safety and ProfitabilitySafety and cost effectiveness are always a challenge with regard

to underground mining and tunneling. For almost 50 years, the

Hermann Paus Maschinenfabrik GmbH has been focused on these

issues and optimizes almost standard vehicles as well as customer

requests for the best solutions.

This year, the Paus LHD (PFL 30S) got a new face lift and is

flameproof designed for more safety and mobility. Paus excels in

lift technology, construction machines, industrial vehicles and, of

course, underground mining and tunneling support worldwide. The

company offers an all-in-one production with an increased aware-

ness of safety and support.

“The people who care,” is the Paus philosophy. To care for cus-

tomers’ needs was the main issue when Hermann Paus founded his

manufacturing company in 1968. He realized the special needs of

this diversified mining industry and that was the first step in today’s

main business. Over the years, the Paus family has developed an

impressive range of mining vehicles, trucks, loaders, scalers, grad-

ers and customized solutions — always with a focus on safety first.

Regarding safety and innovation, all the company’s manufacturing

is centrally located, guaranteeing optimum one-source craftsman-

ship. The same applies for the new flameproof technology, which was

developed at the Paus facilities in Emsbüren.

The LHD (PFL 30S) has had several safety and ergonomic

improvements. The drivers have more stability and comfort with

more space. To enter, the miners use a direct side entrance in-

stead of having the confrontation with the articulated joint behind

the kinematic.

The kinematic itself also changed from the former parallel link-

age to the new z-kinematic to give more power and to increase speed

of dumping. That means easy handling and efficient operations. The

line of sight aspect for underground miners is always a concern. The

Paus design team turned this disadvantage around and developed

a solution that is impressive. They reduced the flameproof rear and

made the motor-block more compact so that the driver’s cab will be

high enough for a better sight toward the rear.

Making a more compact machine is not easy, especially when

it comes to managing temperatures. Under EU Atex regulations, the

motor temperature can be no higher than 150°C. Paus engineered

a five-step cooling system to meet this standard. Exhaust gases

are cooled through inside and outside lines. This awesome system

can cool exhaust gas temperature down to 70°C. Additional flame

barriers placed at the exhaust gas and air intake lines further guar-

antee safety in addition to encapsulated electric parts. For gassy

mines, Paus has added intelligent sensors to the driver’s cab to

signal when gas has been detected.

Paus produced a couple of these Atex flameproof LHDs (PFL 30S)

in 2016 and now they have delivered a Universa 50 as a flameproof

vehicle. The Universa 50 is a chassis onto which many modules

can be attached, such as a tire handler, maintenance unit (with an

optional crane), a charging system for blasting agents, a concrete

mixer and sprayer, or a scissor lift.

Innovative vehicles are Paus’ strength and in related news, the

MinCa 5.1 is now available as a hybrid. It transports five miners

and offers even more space for mining or tool equipment because

of the self-supporting chassis. All-wheel-drive, extremely stable

axles and more stability through oil-immersed multiple disc brakes

reflect the care about safety in mines. The 4-m length shortens the

MinCa 5.1’s turning radius, making it very agile. With mining and

tunneling, there are always challenges and solutions and always

“people who care.”

With safety in mind, Paus designed the MinCa 5.1, which can transport five miners and their gear.

For generations, miners have relied on Dräger and our quality products. We remain

committed to supplying innovative and integrative safety concepts to improve mine safety.

Passion and Know-How perfectly linked together. www.draeger.com/mining

Your safety, our solutions – perfectly linked together.

http://www.draeger.com/mining


The safety consideration for underground miners is a top priority.

With bulk commodities, such as potash and coal, both of which

have faced considerable downward price pressure recently, the

competitive advantage is determined on a cost per ton basis. The

capital and operating costs to extract and transport ore (and coal)

to the surface can be signifi cant, especially over the course of a 20-

year mine life. So, it’s important to choose the right system.

Similar to their counterparts on the surface, underground min-

ers need more power to grow production. They are vitally interest-

ed in automation and they frequently turn to technology to protect

workers and reduce costs. Most of the underground mining special-

ists in Germany are working to meet those needs.

High-end, Shaft Hoisting in CanadaMosaic, a market leader in the fertilizer business and a potash pro-

ducer, partnered with SIEMAG TECBERG to supply and install large,

modern shaft hoisting equipment for its new K3 mine site located in

Esterhazy, Saskatchewan. At a depth of approximately 1,100 meters

(m), the K3 project consists of two shafts. It is one of the largest

potash projects in Canada and is designed to hoist millions of tons

per year. Production is slated for 2018.

The K3 hoist tower contains two advanced technology SIEMAG

TECBERG winders with supporting rope sheave assemblies. The

2011 contract for these machines was awarded by Mosaic to an

international consortium of SIEMAG TECBERG Germany and Con-

verteam (now GE). The order included engineering, manufacturing,

delivery, erection, commissioning and post-project maintenance ser-

vices. SIEMAG TECBERG Germany provided the mechanical equip-

ment and used its U.S.-based offi ce in Milwaukee for local support.

The winder and sheave designs and reviews started in 2011

and continued until mid-2012. The equipment was evaluated using

fi nite element modeling (FEM) tools and designed to comply with

multiple international and local standards including Saskatchewan

Mining Regulations, Canadian CSA, German TAS and consultant re-

quirements similar to South African SABS. In addition, the hoist was

customized to incorporate Mosaic-specifi c hoist experiences and

“lessons learned” to maximize its effi ciency and maintainability.

The six-rope 6-m Koepe production winder handles a 55-

metric ton (mt) payload using a twin drive of 11 megawatts (15,000

total horse power). When operational, it will be the fl agship Koepe

winder within the SIEMAG TECBERG Group and a world leader for

hoisting production.

Both the Koepe and Blair winders are equipped with custom

SIEMAG TECBERG equipment specifi cally designed for mine winder

applications. The Koepe winder is equipped with the BG 100, the

company’s largest slide bearing size (1,000-mm seat), and the

Blair hoist features the BG 90 (875-mm seat). Both winders have

12 BE200 brake element pairs and four-channel closed-loop elec-

trohydraulic brake control systems (providing constant retardation

brake) with SIL3-level components.

SIEMAG TECBERG supplied a six-rope 6-m defl ection sheave

set for the Koepe production winder. A new generation 4-m com-

pensation sheave was developed (patent application in process)

for the Blair service hoisting system. The sheave compensation

system consists of two independent and vertically guided sheaves

connected to two hydraulic cylinders. This arrangement maintains

similar force in the two Blair ropes to prevent unsymmetrical loads

(with direct improvement for safety and rope life). The sheave com-

pensation unit includes a specially designed hydraulic station with

electrical control system, which drives and controls the operation of

the sheaves.

Manufacturing of the equipment was largely completed during

2012. Workshop assembly and factory acceptance tests were com-

pleted in the fi rst quarter of 2013. Following this, the equipment

was packed and shipped to Canada and stored until May 2016

awaiting installation. The SIEMAG TECBERG six-rope 6-m Koepe production winder for Mosaic K3

during installation in November.

The headframe for Mosaic’s K3 shaft rises above the Saskatchewan prairie.

Underground Mining Where Power Meets Safety


Installation began in May 2016 and erection is scheduled to

be finished in early 2017. Cold commissioning (without loads) will

follow this, and hot commissioning (with loads) is scheduled for

later in 2017. This multiyear project required diligent and flexible

management in all phases of the project.

SIEMAG TECBERG’s comprehensive role included hoist and

sheave design, engineering review by third-party consultants, man-

ufacturing with ongoing quality assurance, factory assembly and

acceptance testing, and packaging and transoceanic shipment to a

controlled environment for long-term storage.

Extensive site work follows for SIEMAG TECBERG’s hoists spe-

cialists and crews to install and commission the two hoists and

corresponding sheaves.

Maintaining Engineering Excellence Whenever coal operators face challenging conditions, Eickhoff

has the solution. The German-based equipment manufacturer

has successfully placed its longwall shearer loaders and con-

tinuous miners in some of the most adverse mining conditions.

While excellence in experience and service plays a big role in the

company’s success, Eickhoff also has its own foundry where it

has developed special alloys for tough mining purposes to realize

durability, stability and ease of refurbishment. Eickhoff as a pri-

vately held business has maintained its high engineering stan-

dards for building mining equipment while some of its publicly

held competitors abandoned the coal segment. Fortunately, the

company has diversified into many areas, such as the specialized

gearing for windmills, which allowed them to carry on with min-

ing-related developments despite the global commodity trough.

This allowed the company to prepare for the return of the mining

business. The company has been concentrating on automation

and it retained its software development teams to prepare for the

eventual recovery in the coal market. With multilayered technical

improvements and new developments, Eickhoff is now prepared

for a market upturn in 2017.

“We recently had some customers from eastern Europe revisit

our office for the first time in many years and, as I was explain-

ing the benefits of working with Eickhoff, they stopped me and ex-

plained that they have an Eickhoff shearer loader that has been

running for 30 years,” said Dr. Johannes Krings, director of sales

of mining equipment at Eickhoff. “There was no need to explain to

these gentlemen from the mining industry why they should spend

their money on premium equipment and the concept of least total

cost of ownership.”

Last year, Eickhoff introduced the low-profile Eickhoff SL 300 L

shearer loader and it successfully passed all testing for this fully

automated machine. “We will place it underground in a high perfor-

mance operation soon,” Krings said.

At the other end of the spectrum, Eickhoff is also building a

new version of its SL 1000 with an impressive 8.8-m cutting height

for China. “This is a major step for Eickhoff because it will be the

largest shearer loader the company has ever manufactured, and it

will be the largest shearer loader in the world,” Krings said.

“We are working on continuous sophistication and upgrading of

the whole Eickhoff product portfolio behind the scenes,” said Krings.

“As an example, we are developing more sophisticated alloys in the

foundry. That’s why we are able to engineer such a compact and

powerful shearer loader and that’s also why miners from all over the

world buy the state-of-the-art Eickhoff shearer loaders.”

In December, Eickhoff announced two new orders for SL 300

shearer loaders for the Kakanj and Raspotocje mines in Bosnia.

That increased the current population up to eight Eickhoff shearer

loaders for the Balkan region. This news followed the delivery of

shearer loaders to the Breza and Banovice mines also in Bosnia.

In addition to longwall mining equipment, Eickhoff also sup-

plies continuous miners and they have become quite popular in

South Africa. A well-established South African contract mining

company recently began cutting coal with an Eickhoff CM2H-30

continuous miner at Universal Coal’s New Clydesdale Colliery in

South Africa. Exxaro Coal Central, which currently produces 3.9

South African miners together with the Eickhoff team stand proudly before the CM2H-30 continuous miner before it is deployed at the New Clydesdale Colliery.


LIFE CAN

BE SO SIMPLE

EICKHOFF SL SHEARER SERIES

Highest reliability combined with state of

the art automation features make work at coal

faces the most productive and safest ever.

Eickhoff SL Shearer series represent the

apex of longwall shearer technology.

Even in diffi cult applications and harshest

mining conditions, the most powerful

and reliable solutions are attained

through Eickhoff.

We continually demonstrate why

longwall operators rely on us.

Input

Output

Experience has no substitute · Eickhoff since 1864

WWW.EICKHOFF-INTERNATIONAL.COM:

AUSTRALIA · BELORUSSIA · CHINA · GERMANY · POLAND ·

RUSSIA · SOUTH AFRICA · USA

million mt/y from one surface mine and two underground mines,

recently purchased a CM2H-30 for its Dorstfontein Complex, which

operates three continuous miner sections. Eickhoff now has a total

of 13 continuous miners currently operating in South Africa. Eickhoff

continuous miners are also working in China, Russia and Belarus.

“There are some interesting developments at the Dorstfontein

Complex,” said Dr. Uli Lange, deputy director of sales for Eickhoff.

“They are running our 30-type continuous miner next to a competitive

low-profile prototype machine. The performance of these two ma-

chines is being watched closely by all of the underground coal oper-

ators in South Africa. This Exxaro trial is very high on our agenda and

it looks we’re again defining the performance and TCO benchmarks.”

Eickhoff also had the brand new 36-type continuous miner (3.6-m

cutting height) shipped recently to South Africa. The machine weighs

83 metric tons (mt) and has 2 x 180 kW cutting power. “There is great

potential for these machines,” Lange said. “We took an existing 37

model, which is shorter and lighter, and modified the mainframe

making it longer and heavier for the South African market. The coal

in this region has a high compressive strength. So, we modified the

kinematics of the mainframe as far as the hinge point of the cutter

boom, which allows the operator to apply more power at the face.”

Eickhoff’s South African continuous miner fleet will significantly

grow in 2017 — besides that local success, they see a promising

global market for hard coal equipment sales.

Eickhoff tests a fully automated low-profile 300 SL shearer loader at its fac-

tory in Bochum, Germany.

Looking at the low-profile shearer loader from the deck of the armored face

conveyor, one can see that Eickhoff has engineered it in such a way that it

still has the clearance for high-capacity production.


Advancements in Underground HaulageWhen it comes to haulage, mines have three options: rail, rub-

ber-tired machinery and conveyor system. While the mining industry

drifted away from rail haulage, Matthias Pütz, sales manager for

Schalke Eisenhütte, emphasized it is still a competitive option for

transporting ore. Schalke manufacturers locomotives that are cus-

tom-designed for underground haulage systems.

Schalke is currently negotiating with China on a major pro-

ject. The company shipped the first locomotives to Freeport-

McMoRan’s Grasberg mine in Indonesia in June. Even though

the project was delayed, they installed a test track on the sur-

face to get operational approvals. “A total of 10 locomotives were

ordered for Grasberg,” Pütz said. “The last two will be produced

in the fourth quarter of 2017. When the locomotives begin operat-

ing underground, they will start with diesel-powered systems until

the catenary system is constructed, then they will switch over to

electricity.”

More recently, Schalke has been working with project developers

to reinforce rail haulage as an option at the prefeasibility stage.

“We have been involved with several scoping studies, including the

expansion at Olympic Dam,” Pütz said. “They recently decided to go

with rail and they have started the second stage of the study.”

Pütz has also worked on scoping and bankable studies for

smaller mining companies. “The Seabridge KSM gold mining project

in British Columbia was planning a conveyor system through the

mountain to the mineral processing plant, but we have now con-

vinced them to use rail haulage, especially as it relates to reduced

operating expenses,” Pütz said.

Schalke received its first order in North America last year and

it sees a lot of potential in that market. “In May, we received an

order from Manitoba to replace three old Goodman locomotives with

a semi-automated system,” Pütz said.

Currently, Schake is developing a new locomotive in the 10- to

20-ton range, which could be used for service as well as production.

It would be based on Schalke’s Modutrac system and has the same

parts as a standard locomotive, such as the frame and the driver’s

cabin. This avoids the long delivery times associated with a cus-

tom-made locomotive.

For the last two years, Schalke has been working with the Insti-

tute for Mineral Resources Engineering at the University of Aachen

to develop an inexpensive Excel-based tool to compare the capital

and operating costs associated with the three main haulage sys-

tems. Pütz said it was nearly finished and are awaiting the results.

Energy-efficient Pump Stations for Powered Roof SupportsModern roof supports require higher pressures, bigger cylinder

diameters, and faster advance rates than their predecessors. All

these requirements depend on the high-pressure pumps. At the

same time, longwall operators are looking for ways to significant-

ly reduce noise levels and improve energy efficiency. In response,

KAMAT has developed a new series of speed-controlled plunger

pumps for pressures up to 3,500 bar and motor ratings up to 800

kW. The company combined an upgraded mechanical drivetrain with

a variable speed controller, which allows one system to replace mul-

tiple small pumps with one bigger and well-controllable high-pres-

sure pump or with a master-slave combination.

The forces introduced into powered roof supports are increasing

considerably along with longwall face lengths and the depth of min-

ing. As a result, the hydraulic pressures and cylinder diameters of

the shields are increasing as well. The higher cutting speeds of the

shearer loaders additionally require a faster advance of the shield

supports. All these factors are setting high requirements for the ef-

ficiency of the hydraulic stations in use.

Adding to this are new, more stringent requirements for the en-

ergy efficiency and noise levels. The pump stations are located more

and more often in the immediate vicinity of the longwall controls in

the headgate. While total cost of ownership and energy costs are

a concern, longwall operators are also looking for more compact

design because of the confined space.

KAMAT understands these conditions and has successively

developed a new pump series that features a new drivetrain. It is

based on the high-pressure plunger pumps, which have been used

by the mining industry for decades.

“The reduced noise level requirement was difficult to meet with

the existing drive concept of the KAMAT pumps because the crank-

KAMAT combined an upgraded mechanical drivetrain with a variable speed controller. The new system replaces multiple small pumps with one larger pump.


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shaft, which moves the plunger via crossheads, had to be asymmet-

rical to accommodate it in the previously undivided housing,” said

Dr. Andreas Wahl, CEO, KAMAT. “The asymmetry resulted in stronger

vibrations, which made it difficult to achieve acoustic decoupling by

means of damping elements.”

The new drivetrain features a split housing in which a symmet-

rical, balanced crankshaft takes over the power transmission be-

tween the drive and the plunger. “The newly designed double-helical

gearing also helps to improve the smoothness in operation and to

reduce the noise emission from the pumps,” Wahl said.

The new design is now incorporated in the triplex pumps of the

performance classes from 80 kW to 400 kW. It also forms the basis for

the design of the quintuplex pump drives in the performance classes

from 530 kW to 800 kW, which KAMAT has developed for series produc-

tion and has the potential to bring about significant cost savings from

an operator’s point of view when large volume flows are requested.

The mechanical part of the drive creates the prerequisite for a

demand-oriented, variable speed control of the pumps, which is one

of KAMAT’s core competencies. The power transmission design de-

tails include large surfaces for a low surface pressure and the amply

dimensioned crosshead. “They ensure an excellent, hydrodynamic

lubrication of the pump drive at the spots with the highest loads

even at a low rotational speed,” Wahl said. “Since KAMAT plunger

pumps are working at full operating pressure over a speed range

from 10% to 100%, the plunger pumps are operated in an ener-

gy-efficient and demand-oriented way at partial flow.”

The first KAMAT quintuplex pumps for pressures up to 3,500 bar

were another development stage on the basis of the redesigned,

energy-efficient triplex plunger pumps, Wahl explained. “This de-

velopment was initiated in response to the fact that the (water)

hydraulic systems of various high-pressure plunger pump applica-

tions — and notably those on longwalls in the mining industry and

descaling systems in the steel industry — are getting larger and

larger,” Wahl said.

Today, the operators are using multiple large triplex pumps giv-

en that the volume flow of these pumps is limited by design, but

also for reasons of the high pressures involved. The cylinder volume

is limited by cavitation, which implies that it only makes sense to

produce triplex pumps with ratings of “only” about 400 kW.

The basic design of the new triplex pumps then opened up the

option to develop, on their basis, the first quintuplex (five-cylinder)

New double-helical gearing reduces the noise emissions from the pumps.


pumps with a rating of 530 kW or 800 kW and the capability to

reliably deliver distinctly larger volume flows than triplex pumps.

The advantages for the operator result from the “economy of

scale.” A large pump is working far more cost-effectively than two

or three smaller ones, and clearly needs less space — an important

argument in most modernization projects.

A lot of detailed design work was, however, required to transfer

the basic concept of the triplex design to the quintuplex pump. The

crankshaft, for example, is supported by multiple bearings, and the

crossheads are oil-spray lubricated rather than splash lubricated

so that sufficient lubrication of the center crossheads is ensured as

well. The crankshaft is supported in special split bearings. KAMAT

has managed to keep spare parts stocking economical by using

many common triplex pump parts.

The new quintuplex pumps offer the same advantages as the

redesigned triplex pumps. They operate at extremely low noise and

low-vibration levels and they work at full operating pressure over

a speed range in conjunction with speed-controlled drives. Thus,

they can ideally be adapted to the respective volume flow require-

ments, and one single pump is sufficient due to a very large speed

control range.

“This is primarily achieved through the pump’s capability to

rotate slowly without affecting the hydrodynamic lubrication of

the highly loaded drive elements of the crosshead in particular,”

Wahl said. “The corresponding design prerequisites are, among

others, amply dimensioned crossheads with large surfaces, which

absorb a high-surface pressure and preserve the continuity of the

lubricant film.”

Operators see another advantage in the fact that the flow rate

of KAMAT pumps is not controlled through circulation valves in on/

off technique but through an electronically controlled speed change

of the pump. As a result, wear is significantly reduced since the

pump, the pipes and the valves are subjected to far less load. Since

the valves of circulation valve controls tend to switch multiple times

within a few seconds under certain circumstances, extremely high

loads are imposed on the entire pump system thus generating pres-

sure shocks.

The first 530-kW quintuplex pump was followed by an 800-kW

model. The two versions are already produced in series, and the

operators benefit from significant cost savings in terms of ener-

gy consumption and maintenance and service bills: Three 800-kW

pumps — one each as a master, slave and standby unit, a common

constellation — are able to generate even very large volume flows

at maximum pressures up to 3,500 bar, and thus typical face pres-

sures of 350 bar to 380 bar, at highly economical rates.

Another control combination, which is also quite common: The

master pump is speed-controlled via frequency converters when two

high-pressure pumps are in use. The slave pump takes over the basic

load once the requirements exceed the delivery capacity of the mas-

ter unit. Therefore, only one single-speed-controlled pump is needed

to cover a very large control range, which is a substantial cost benefit

especially for the mining industry considering the expenses caused

by an ATEX-compliant frequency converter, which is approved for use

in underground mines. The option of operating all pump models also

in the vertical position creates the prerequisite for a space-saving,

vertical installation in pump stations close to the face.

The next development stage is already under preparation: In the

medium term, KAMAT will add a quintuplex pump with a rating of

1,200 kW to its portfolio.

New Ultraclass LHD

The latest development of GHH Fahrzeuge is the Load Haul Dumper

(LHD) LF-21H with a payload of 21 metric tons (mt). The LF-21H is

the most powerful and efficient machine and the largest LHD in its

class, according to the manufacturer.

The LF-21H is equipped with the latest generation of GHH’s

hydrostatic drivetrain, the Efficient Drive System (EDS). The EDS

is optimized for the rough conditions of underground mining and

achieves both significant efficiency as well as productivity gains

compared to conventional hydrodynamic drivetrains. In combination

with an intelligent monitoring system, it guarantees simple opera-

bility as well as maintainability.

Reduced fuel consumption, very low brake and tire wear as well

as high robustness of the system minimize the operating costs. The

eco-friendly engine complies with the latest standards, EU Stage IV

and EPA Tier 4 final, and thus minimizes the underground ventila-

tion requirement and provides 375 kW power.

The focus is on ergonomics with a large foot box, two-pedal

control with an inch-function and controls adjustable for all oper-

ator sizes.

The LF-21H is available in different cabin variants for highly

efficient mining in low seam applications of min. 2.5 m. A Z-link

for hard rock applications is designed for high breakout forces and

loading of matching dump trucks. A low profile version of this Z-link

and the lowest machine height of its class provide superior visibility

even in confined spaces.

A great variety of optional assistance systems such as collision

avoidance systems and the automatic loading mode grant a high

safety standard and simple operation.

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Last year was a big year for thyssenkrupp Industrial Solutions. They

announced several new pieces of equipment and services at bau-

ma and MINExpo. Then the company embarked on a reorganization

plan where its business units were restructured and focused more

strongly on sectors and customer groups. All of these moves were

not only made to reduce costs and improve service, but to also con-

sider step changes as to how projects are engineered and managed.

“We now have a dedicated organization for project manage-

ment and engineering and other central services regarding project

execution such as commercial project management, logistics and

procurement,” said Thomas Jabs, executive vice president, mining

systems for thyssenkrupp Industrial Solutions. “All of that is now

combined into one entity, which is referred to as a Network of Excel-

lence. The idea was to strengthen the focus of the company’s core

plant engineering business by combining all these project execution

disciplines into one entity, making us more competitive and flexible

in terms of resource utilization.”

thyssenkrupp Industrial Solutions has eight business units and

one of those is Mining Technologies. Service is another business

unit. “Service will be a cornerstone of the new organization,” Jabs

said. “The target is to offer our clients technical solutions as well as

services for the whole lifecycle of a plant, and at the same time, to

Material Handling: Moving

Minerals Engineering Modern Crushing and Material Handling Installations

Designing crushing and conveying installations, such as this truck dump, which handles two haul trucks, thyssenkrupp’s semi-mobile installations avoid the

concrete work to a great extent and allow for pre-assembly of large modules, reducing the initial cost.


expand our local proprietary business. The service business unit will

include service centers, spare parts business, upgrade refurbish-

ments and asset management.”

The Mining Technologies business unit has three different

operating units: mineral processing (crushing, grinding and pyro

processing), materials handling (stockyards and port handling sys-

tems) and mining systems (continuous mining including the large

crawler mounted machines and heavy-duty conveying including

overland conveying systems). “Each operating unit has global re-

sponsibility for its projects and products,” Jabs said. “In the future,

our performance will be solely evaluated by the combined global

success of the project.”

This is a new concept within thyssenkrupp Industrial Solutions

and they are eager to prove it will work. They recently submitted a

proposal for two large conveyor systems for two different customers

in Asia, most likely using gearless drive technology.

New Approaches to CrushingLast year, thyssenkrupp unveiled the huge 63-130 gyratory crusher,

first at bauma and then at MINExpo and the first two machines have

been ordered. The crushers will be supplied as part of semimobile

crushing plants for a copper ore mine. “The tendency with crushing

installation investments is to focus on operating expenses,” said

Frank Drescher, head of product division crushing technology, thys-

senkrupp. “We are currently working on several in-pit crushing and

conveying (IPCC) projects, and this new gyratory crusher, which is

lower in weight and higher in capacity, represents a new path for-

ward for us.”

One of those major projects that combines conveying systems

and crushing plants is the Cuajone project in Peru. “At this instal-

lation, a gearless conveyor serves one of the largest semimobile

crushing installations in the world,” Drescher said.

When thyssenkrupp began development on the 63-130, they

were expecting positive feedback because it opens new possibilities

for plant design. “We can place in those modular plants a choice of

crushers from the 75 to the 130,” Drescher said. “That gives us a

great deal of flexibility to respond quickly to requests.”

Many of the competitive mining-class gyratory crushers on the

market today are being used for installations with concrete founda-

tions. Other manufacturers were not as much concerned with out-

of-balance forces, but thyssenkrupp had a keen understanding of

them because they were using gyratory crushers to large extending

semimobile steel structures.

“That’s where we have a tremendous advantage,” Drescher

said. “The extremely efficient operation of the gyratory crusher pro-

longs the lives of these semimobile installations. With the 130, we

have been focused not just to make the equipment bigger and more

powerful, but managed also to reduce the forces substantially,”

Drescher explained.

The semimobile installation avoids the concrete work to a great

extent and allows for pre-assembly of large modules, which reduces

the initial cost. “Further, these systems provide the option to relo-

cate the crushing plant within the mine following the excavation

and to reduce the truck fleet and cost involved thereof,” Drescher

said. “This could be the deciding factor for many projects.”

In the last 10 years, the majority of thyssenkrupp’s underground

crushing installations have been designed with gyratory crushers

mounted in a stationary system, many of them with thyssenkrupp’s

split shell design to reduce component dimensions and weight for

transportation. Most are complete systems that include conveyors

and the company only sees that number growing.

“More and more mines today prefer the packaged crushing

plant based on the raw feed capacity and feed required by the pro-

cessing plant,” Drescher said. “That approach puts us in more of an

OEM system supplier position.”

Maintaining a certain level of technology, thyssenkrupp has

managed to optimize pricing to a point where they can compete

in the standard machine business. “We are working directly

with local markets and dealers and that’s a fundamentally differ-

ent view from the ‘tailor-made’ mining business. It’s a different

approach to engineering as well as keeping equipment in stock,”

Drescher said.

Jabs explained that the tailor-made solutions for mining are

part of the company’s DNA. “That’s how we roll,” Jabs said. “But

now thyssenkrupp is trying to transfer that DNA also to the mass

mining market. Some of these smaller cone crushers and other

items are sold as a commodity.” The custom-made mindset has

prevented the company from competing for the business in these

markets in the past.

“We have dedicated teams serving this market now,” Drescher

said. “Local business units have adopted this very quickly and it’s

a driving element to be closer to the customer and to provide those

services quickly.”

Bridging GapsWith Grinding TechnologyUsing the expertise within the business area, thyssenkrupp can en-

gineer systems to mine and transport phosphate and fertilizers from

pit to port. “Working with our colleagues in Dortmund, who design

fertilizer plants, thyssenkrupp can design the entire beneficiation

process as well as the ship-loading process,” said Uwe Schuh, head

of department grinding technology mineral processing, thyssenk-

rupp. “We are currently looking at several projects in North Africa.”

Phosphate can be exported as ore (phosrock) or a liquid (phos-

phoric acid). India imports a lot of phosrock; other destinations,

such as Brazil, would rather receive phosphoric acid.

thyssenkrupp has been looking at fine grinding as a way to re-

duce water and energy consumption (See Minerals Processing, p.

32). Using the experience gained with phosphate grinding in dry

regions, the company believes it can parlay that into savings for

other metal recovery plants. They recently received an order from

Ma’aden in Saudi Arabia to install crushing and dry grinding equip-

ment within a fertilizer plant in a very dry region. “This will be the

first HPGR application for phosphate ore,” Schuh said. “They have

limited water resources and this installation will come online during

the first quarter of 2017.”

Developments with grinding have helped bridge the gap

with thyssenkrupp as it relates to its service initiatives. “Our service

center in Chile was developed to support HPGR refurbishments,” Jabs

said. “Today, however, it is acting as an equipment rebuild facility. We

recently had a shovel undercarriage in for a rebuild. There is no limit

to the services that we can provide.” The company could also say that

about their service centers, located near Perth and Johannesburg.

Reducing or Eliminating TrucksThe Mining Technologies business unit within thyssenkrupp contin-

ues to develop solutions to eliminate or reduce the use of trucks.

“When we discuss new projects with mining clients, the first thing

they want to evaluate is whether it is possible to mine and transport

ore without trucks — that is a significant change in thinking from

just a few years ago,” Jabs said. “Even customers in the oil sands

have started to investigate new mine developments without trucks.

Whether they can accomplish it or not is yet to be seen, but at least


they are thinking about it at an early stage. That increases the re-

quirements for fully and semimobile crushing stations.”

The backbone for all these techniques is the conveyor system.

“We have brought forward many developments with gearless drive

systems and we continue to build our position,” Jabs said. “During

2016, thyssenkrupp acquired the Overland Conveyor Co. in Denver

and this brings even more conveyor expertise onboard.”

The company is still refining solutions for steep-angle convey-

ing. “Right now, we see the greatest potential with the Megapipe for

steep angle conveying,” Jabs said. “Working together with Contitech

and Siemens, thyssenkrupp has made a significant investment in

terms of tests and prototyping. We conducted a lot of tests and we’re

sure that this is something that is going to fly quickly.”

Beyond that, thyssenkrupp is always on the lookout for other

solutions, Jabs explained. “There is conventional conveying and then

we have some big ideas, but we need something to bridge the gap,”

Jabs said. “The imagine gap between what miners are accustomed

to seeing and the possibilities that are out there. It’s two extremes.

The Megapipe is definitely in between what currently exists and the

extreme steep angle conveying solutions.” IPCC was a revolutionary

change 10 years ago, Jabs explained, and now steep-angle convey-

ing will be the next game changer.

Conveyor Ensures Dust-free Transportationof Ore ConcentratesTransportadora Callao S.A., the logistics operator of a special cargo

terminal at the Port of Callao in Peru, relies on a pipe conveyor to

transport zinc, copper and lead concentrates from the warehouse to

the terminal. With its ability to navigate curves in three dimensions,

the conveyor could be optimally adapted to its 3,000-m routing

course. More importantly, the conveying system prevents the con-

centrates from escaping into the environment, ensuring dust-free

transport to the ship’s holds. The Beumer Group handled the engi-

neering, procurement (including the steel structure), construction

management and commissioning of the system.

Located on the Pacific Ocean, Callao is a large Peruvian city,

with the largest airport in the country and one of the most import-

ant fishing and commercial ports in South America. A modern ship

loading terminal for ore concentrates was built in this port and it is

operated by Transportadora Callao S.A.

About 75% of Peru’s imports and exports pass through Callao.

To satisfy the increasing demand for these valuable materials, the

Peruvian government decided to expand the port. Besides addition-

al storehouses, the plans also foresaw the largest, most modern

ship-loading terminal in the country. Peru also wanted to change the

way the raw materials were transported to the ship-loading areas.

Before the construction of the special terminal, trucks were used to

transport the concentrates from the warehouses to the port terminal.

“Since Transportadora Callao started its operation, they could reduce

the truck transports by 130,000 per year,” explained Victor Sam, CEO

at Transportadora Callao S.A. The company, a consortium comprising

five enterprises from the mining and port industries (manufactur-

ers and warehouse logistics operators), obtained a license from the

state of Peru for building and operating the necessary infrastructure.

The mines in central Peru transport their concentrates to the

warehouses about 3 km from the port. That distance required a fully

enclosed material handling system. Transportadora Callao opted for

the Beumer pipe conveyor. “Together with the responsible persons

from the port, we developed a solution that is perfectly adapted to

the routing and the ambient conditions,” said Helmut Wolf, pipe

conveyor engineer for Beumer.

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The pipe conveyor not only protects the environment, it also

conveys over long distances and navigating tight turns, which re-

duces or eliminates transfer towers and the associated costs. The

engineers use different dimensioning programs to determine the

ideal belt design. They calculated the tractive forces and forces that

arise during acceleration and deceleration and also determined the

possible curve radii. Special idlers and bearings reduce noise levels.

“This improves the quality of the employees’ day-to-day work envi-

ronment,” Wolf said.

“Noise measurements along the pipe conveyor resulted in values

that are consistently far below the permitted limit values,” Sam said.

Beumer supplied and installed a pipe conveyor with a cen-

ter-line distance of 3,195 m. “Due to the system design and the

required system capacity, we designed it with a diameter of 400

mm,” Wolf said. “The conveyor transports 2,300 metric tons per

hour (mt/h), at a speed of 4.5 m/s and is driven by three 650-kW

motors. We equipped the system with filters, strippers, a dedusting

unit and a control system.”

Trucks or trains offload concentrate at the storage area, where it

is transported to an open access station. “A big challenge for us was

integrating the pipe conveyor into the existing network,” Wolf said.

The pipe conveyor is the connection between individual belt conveyors

from various manufacturers.” The concentrate is received by a 43-m

feeding conveyor that transfers it to the pipe conveyor at a height of

6 m. A dedusting unit ensures that no material is emitted during this

process. At the end of the route, the conveying system runs along the

seaside in the naval port of Callao to the transfer tower. Here, the

belt opens automatically and transfers the material to another belt

conveyor that conveys the ore to the ship-loading system.

“This modern system, in operation now for more than 17

months, has increased concentrate loading times by 500% and

reduced the ship’s waiting time until loading by more than 80%,”

Sam said. “These advantages passed savings on to the exporters

and has improved the competitiveness of the Peru’s mining sector.”

Transportadora Callao is now able to handle ships for bulk products

of up to 60,000 DWT without obstructing the work in the other termi-

nals of the Port of Callao.

Automation & DigitalizationA pioneering technology leader for open-pit mining and bulk materi-

al handling systems, ABB Germany through its Center of Excellence

in Cottbus offers decades of expertise in electrification and auto-

mation of the entire mining chain, from pit to port. The ABB team

provides integrated products, services and solutions to help mining

customers optimize the value chain.

A great example of this expertise is successful, long-term

partnership with Joy Global, a leading mining equipment supplier.

During the last 10 years, ABB Germany has equipped 75 electric

shovels with AC multidrive lineups, which are specifically developed

for the most adverse conditions in open-pit mining. Daily, these

shovels encounter high shock and vibration loads as they crowd and

load rock from the face in some of the most challenging environ-

mental conditions from the top of the Andes to the Arizona desert.

ABB’s proven ACS800 low-voltage drive systems are specifically de-

signed and modified for the requirements of loading equipment.

ABB is also participating in the electrification and automation of

a 13-km-long conveyor system at the historic Chuquicamata copper

mine. Once the project is completed, the conveyor system will be one

of the world’s largest and most complex systems and will deliver cop-

per ore from the new underground mine directly to the concentrator.

ABB engineered the gearless drives, motors, instrumentation and power

supply for the 13-km overland conveyor at Chuquicamata.

With its ability to navigate curves in three dimensions, Beumer recently installed a 3-km pipe conveyor to transport concentrate to a new terminal at the

Port of Callao in Peru.


Chuqui is one of the largest open-pit copper mines and the

second deepest open-pit mine, located in the Atacama Desert in

northern Chile. The mine has been operating since 1910 and today it

is operated by Corporación Nacional del Cobre (Codelco) — Chile’s

national copper mining company and the leading copper producer.

To cover both steep gradients and long distances, the conveyor

fl ights will be powered up to 20 MW and 55 MW in total. In the fi nal

stage, the system will transport more than 11,000 tons per hour of

material, the same freight as approximately 158 railcars per hour.

ABB’s delivered a complete power and automation solution,

which includes gearless drives, motors, instrumentation and power

supply products. The equipment will be custom-engineered to on-

site requirements to optimally power, control, measure and actuate

the conveyor system. The solution will fully integrate the belt’s power

and automation through ABB’s fl agship 800xA control system, com-

bined with a Mining Conveyor Control Program (MCCP) to ensure

optimum power quality and control across the entire system.

A key part of ABB’s delivery is the gearless conveyor drive sys-

tem. This is a state-of-the-art solution to meet the extremely high

load requirements and the necessary power availability, which

would not have been achievable with a conventional drive solution.

This gearless conveyor drive system eliminates the gearbox from the

motor, thus signifi cantly reducing the number of main wear parts,

resulting in less maintenance needed and ensuring a longer lifes-

pan of the solution. Other advantages are the considerable reduc-

tion in the drive system’s footprint and the amount of instrumenta-

tion required. Less parts increases the reliability and effi ciency of

the overall conveyor system by several percentage points.

StockyardManagementSystemDemonstrating the trend toward increasing digitalization, ABB

offers a fully automated terminal management system or the

stockyard management system (SYMS). The fi rst SYMS has been

running at an iron ore distribution hub in Malaysia for two years

now and the results have shown that it performs better than

manual operations.

The Teluk Rubiah Maritime Terminal is Vale’s fi rst fully au-

tomatic operating port, which uses its ERP System (GPV Portos)

to create work orders for the port and yard operations, delegate

them as jobs for material movement to the control system, and

execute them by unmanned operating yard machines. The SYMS

receives production data from Vale’s Production Information Man-

agement System (PIMS) and distributes it to the Process Control

System (PCS) to control the machinery. The scope of supply also

included the design, engineering, delivery, installation, testing

and commissioning of ABB’s 800xA PCS to manage all plant

equipment at the terminal, including all ship unloaders, conveyor

belts, stackers and reclaimers. The unmanned yard machines are

assisted by 3-D pile scanners and a GPS positioning system to

ensure the highest level of accuracy and precision in order to

achieve highest productivity.

Before any material movement starts, all planned activities are

validated by the SYMS for the correctness of the selected material

quality, suffi cient space at the assigned destination to stack, or if

enough reclaimable material is available to fulfi ll the job. In case

of a valid status, the import, export and blending jobs are executed

by the unmanned operating yard machines, which are fully auto-

mated. The movement of the material is monitored by a material

tracking feature and provides the operators real-time information of

the stock and material movement status. A reporting feature with a

mass balance and material movement overview, as well as a 3D-Cli-

14. MiningForum

01. & 02.06.2017

Estrel Berlin

Mining is the Future

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NEW: Schedule

is online!

Accompanying

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MININGFORUM

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ent, enables easy management and maximizes performance. With these features, an accurate ratio control in blending operations en-sures the highest material quality standards. The reclaiming rates will be monitored and controlled to meet the strict quality require-ments of Vale customers.

ColombianCoalLoadingSystemLast year, FAM Förderanlagen Magdeburg commissioned a coal handling system for the Port of Mamonal in Cartagena, Colom-bia. The use of modern conveyor technology now helps to transportand load coal effi ciently, safely and in a more environmentally friendly method. Addressing the crowd at the opening, Colombian President Juan Manuel Santos referred to the $160 million project as an “infra-

structural revolution” that will expand the export opportunities of his country and immensely improve its competitiveness. The new port has created some 500 new jobs and another 470 directly or indirectly connected with port operations. The system consists of a 750-mt/h stacker and two 2,750-mt/h scraper reclaimers. A network of fi ve 2,750-mt/h conveyors move coal from the reclaim piles to a 2,750-mt/h radial-type quadrant shiploader. The stacker has a cascade chute installed at the tip of the boom that not only helps to decrease dust but also to optimize the fl ow velocity of the material and to facilitate a softer landing to ensure that the grain size of the bulk material remains largely un-damaged. The shiploader can fi ll ships up to 70,000 DWT without moving them.

Colombian President Juan Manuel Santos addresses the crowd at the grand opening of a $160 million project to improve coal handling systems. Designed and engineered by FAM, the system consists of a stacker and two scraper reclaimers (inset photo). A total of five conveyors move coal from the reclaim piles to the 2,750-mt/h shiploader.

Teluk Rubiah Maritime Terminal in Malaysia is Vale’s first fully automatic operating port. ABB’s process control system manages all plant equipment at the terminal, including all ship unloaders, conveyor belts, stackers and reclaimers. The unmanned yard machines are assisted by 3-D pile scanners and a global positioning system.

LONGWALL USAExhibition & Conference2017

WWW.LONGWALLUSA.COM

2017 LONGWALL USA:

STANDING STRONG.

June 13-15, 2017 • David L. Lawrence Convention Center, Pittsburgh, PA USA

Longwall USA returns to Pittsburgh from June 13–15, 2017, and

we’re planning a great event. Political and social pressure

against the industry are stronger than ever before, but we are

proud of the role we play in powering America’s industries and

bringing energy to the homes of millions of our fellow citizens.

For 2017, we have expanded opportunities for exhibitors and conference

attendees and we will be celebrating the unique role that coal has played

throughout U.S. history. This is your invitation to join us as an attendee,

exhibitor, sponsor, or speaker.

Visit us online or call us today to find out how you can take

part in this important show.

This is Your Invitation to Participate

Contact for More Information:

Michael Schoppenhorst

Show Director

E: [email protected]

Ph: +1 678 822 9801

http://WWW.LONGWALLUSA.COM



Water and energy savings have become more and more important

for miners worldwide. “We introduced HPGR to the mining industry,”

said Uwe Schuh, head of department grinding technology mineral

processing, thyssenkrupp. “We still consider ourselves to be the

market leaders.

Borrowing a concept from the cement industry, thyssenkrupp

is proposing dry grinding up to approximately 150 microns. “This

concept would eliminate the conventional milling stages and report

directly to the downstream beneficiation processes,” Schuh said.

“The concept consist of a combination of HPGR and air classifiers,

and it would be of particular interest to iron ore processing plants.”

Eliminating part of the wet circuits (grinding) would signifi-

cantly reduce water consumption.

“For the fine grinding (down to 20 microns) of disseminated

ore to liberate metals, tower mills could be an option, according

to Schuh. Recently, thyssenkrupp signed a cooperative agreement

with Eirich, the company that invented the tower mill. “Eirich’s up-

per limit for tower mills was 1,500 hp and under the agreement,

we will develop a 6,000-hp tower mill,” Schuh said. “In the future,

we see the combination of the HPGR with a tower mill positioned

downstream.”

Selecting the Proper Pump to Handle Concentrate Many gold operations process ore through autogenous grinding

mills. Ground ore is classified for size through hydrocyclone sepa-

rators. Ball mills regrind the coarse material. The undersize reports

to flotation where the sulfide minerals are separated, concentrated

and sent to a thickener-filter press circuit prior to roasting.

The thickener-filter press circuit reduces the amount of wa-

ter in the flotation concentrate, which is typically handled using

horizontal centrifugal pumps. The use of this type of pump can be

counter-productive because water must be added on the thicken-

er cone bottom to assist transport by the pump. Also, gland seal

water must be added to the centrifugal pumps in the two pump-

ing stages. In total, the volume of water introduced back into the

Mineral Processing: Recovering

More with LessMinimizing the Use of Water and Energy

After introducing high-pressure grinding (HPGR) technology to the mining industry, thyssenkrupp plans to integrate its use with tower mills to reduce water

consumption at mineral processing plants.


thickened underflow fed to the filter press can be increased by as much as 25%.

One gold operation in Nevada recently replaced the centrifugal thickener underflow pumps with ABEL series EM 100 electromechan-ical diaphragm pumps. Cone water additions and gland seal water were no longer required. Also, the maintenance costs associated with the thickener underflow pumps were greatly reduced.

This same plant’s filter press used centrifugal slurry pumps for its feed pumps. The wear on the centrifugal pumps was consider-able with pump wet ends wearing out as often as every two weeks, and costing as much as $20,000 to replace each time. Downtime and lost production mounted with each repeated occurrence.

To mitigate the problem, the centrifugal filter press feed pumps were supplemented by ABEL series HMD-G-80-1000 piston-dia-phragm pumps. The ABEL pumps employ a hydraulically balanced elastomeric diaphragm, ideal for moving abrasive slurry at higher pressures. By working in parallel, the centrifugal pump “fast-fills” the filter press at lower pressures, then hands over consolidation of the press cycle to the ABEL. The resulting pump maintenance costs and downtime were greatly reduced. Filter cake quality improved due to the positive displacement action of the ABEL pump.

The plant has since added another thickener-filter press process train to increase gold production. ABEL EM 100 pumps were speci-fied for thickener underflow and ABEL HMD-G-80-1000 pumps were specified for filter press feed duty.

The ABEL HM series pumps are hydraulically driven piston-di-aphragm pumps. Reciprocating the motion of the piston moves an elastomeric diaphragm by means of a hydraulic end. Ball checks and seats on the product end are available in various materials. This characteristic design allows the pump to transfer abrasive slurry or sludge at pressures up to 1,450 psi (10 MPa).

Aspirational FlotationA lot of mineral processing professionals are classifying the flotation technologies into three groups: mechanical agitator flotation, pneu-matic flotation and column flotation. This is a mistake as column flotation is a form of pneumatic flotation, explained Lutz Markworth, head of product management flotation for MBE Coal & Minerals

Technology. “A lot of different pneumatic flotation technologies are available on the world market,” Markworth said. “The flow direction of the feed and the air is important. Some technologies use a con-current flow, while others rely on a counter-current flow. And the flow

of aerated feed pulp is arranged as downstream, upstream or in a tangential direction into the separation vessel.”

Other important considerations for pneumatic flotation are the needs for a high efficient reagent conditioning process prior to the separation vessel, the creation of perfect air bubble size range and amount, as well as the high efficient attachment of the air bubbles to the mineral particles.

The upstream pneumatic flotation principle, realized in MBE’s PNEUFLOT cell, generates the air in a special designed Venturi-based aerator on top of the separation vessel, Markworth explained.

To float fine and coarse particles simultaneously with improved efficiency, MBE Coal & Minerals Technology developed in 2015 and installed in 2016 a new designed froth channel discharge system for potash, reverse iron ore and coal flotation with excellent results in terms of recovery and yield.

The PNEUFLOT technology, according to Markworth, is the only one using upstream flotation process in one machine. “After leaving the ceramic nozzles with an upward motion into the separation ves-sel, coarse particles that are not perfectly attached to air bubbles at that stage are ‘shot’ into the froth zone, making contact with bigger air bubbles and are discharged properly into the new designed froth channel system,” Markworth said.

The coarse particles are discharged into the froth channels be-fore any sedimentation can take place. Froth discharge velocity can be controlled and set to an optimal condition for all kinds of froth characteristics. Markworth believes the froth channel discharge system could improve recovery by 6%-8% in the same machine at the same flotation time for potash and silica flotation as well as 9% more yield in coal flotation.

An ABEL EM 100 pump is being used as a thickener underflow pump.

The new channel system discharges froth for reverse iron ore flotation in Brazil.


Last year, Innogy announced its plan to acquire Belectric Solar and Battery Holding GmbH, a world leader in system design and engineering, procurement and construction (EPC) services for large-scale solar, storage and hybrid systems since 2002. The acquisition was expected to close in early 2017. Belectric has designed and implemented hybrid energy solu-tions since 2009. Those systems include a combination of photovol-taic power plants, diesel gensets and other energy storage options. In the development of the hybrid systems for mining applica-tions, Belectric is relying on the vast experiences of Innogy’s sister company RWE Technology International GmbH, a world leading consultant for continuous mining and in-pit crushing and convey-ing (IPCC) systems. Supplying electricity to remote mine sites often requires a signifi cant capital investment and operating expenses related to both fuel costs as well as operation and maintenance (O&M) costs for diesel gensets. Hybrid energy systems, which combine different electricity sup-ply sources, offer a cost-effective energy supply solution for mining operations, especially if the mine is located in an extremely sunny location. Once installed, the cost for solar power does not fl uctuate. Moreover, the O&M costs of the solar and storage systems are in general much lower than the diesel system. The hybrid system is managed by a plant controller, which guarantees a stable and reliable electricity supply regardless of the source of energy used at any given moment. Inexpensive solar energy is consumed at fi rst priority while the remaining energy is supplied by the higher-cost diesel system. The system dynamics can further be enhanced by adding a battery storage system.

Solar inverters provide reactive power day and night, supporting voltage stability for the mine’s power grid. This can be a signifi cant additional benefi t for weak power grids where voltage fl uctuations may lead to unexpected downtime. The hybrid system design targets the lowest possible cost of en-ergy as the main objective while considering technical, operational and commercial constraints. The system is scalable and modular and it’s relatively simple and cost-effective to install. Partly con-tainerized, it could be easily relocated together with all other infra-structure at the mine site. Belectric conducted a case study recently on a mine site in Southern Africa. The mine site operated eight diesel generators with a total capacity of 24 megawatts (MW) and consumes 134 gigawatts per hour (GWh) each year at an expected average cost of $0.31/kWh over the mine life. A hybrid system at this mine site would reduce the costs related to diesel energy by 24% with a total energy cost savings of approximately $56 million over the mine life. “As was demonstrated in multiple hybrid energy projects and case studies in the mining sector conducted by Belectric, hybrid energy systems can be a signifi cant enabler for the obvious need of mining companies to reduce their operational costs and to limit their fuel price exposure,” said Gal Bogin, Belectric’s chief sales offi cer. “The current maturity of the solar and hybrid technologies together with Belectric’s design and implementation experience mean this is the right time for mining companies to benefi t from cheap and reliable solar energy.”

Navigation Technology for Marsand the MinesThe German Aerospace Center has developed a navigation technology for future Mars missions, which is capable of navigating without GPS satellites. This innovative technology has been further refi ned by DMT.

Navigation with the DMT Pilot 3-D works similar to the human eye; an inertial measuring cell determines the actual position of the device while two cameras observe the motion relative to the environmental setting — these are the “eyes” of the system. A high-performance processor uses this data to calculate the position and orientation in real-time. As the system operates in-

Innovations: Renewable Energy

Reduces Mining Costs

The hybrid system delivers the most cost-effective source of power.

The containerized hybrid energy system (inset) stores energy and manages power supply sources.


ABEL GmbH, 21514 Buechen, Germany, [email protected] ABEL Pumps L.P., Sewickley, PA 15143-2339, USA, [email protected]

He likes it

we pump it

For difficult pumping of tailings, slurry

or paste, meet the ABEL heavy duty

HM series piston-diaphragm pump.

Designed for the most challenging tasks

in mines throughout the world.

Learn more about our mining competence

at www.abelpumps.com

dependent of light or horizon line-of-sight, it is ideal for precise

navigation in closed environments without GPS access such as un-

derground mines. It had the ability to assess the surrounding area

underground and provides digital images for 3-D documentation.

In addition to system technology development and manufacturing,

DMT also coordinates worldwide distribution. They will present the

technology at the 2017 Mining Forum in Berlin (June 1-2, 2017).

More information on the 2017 Mining Forum is available online at

www.the-miningforum.com.

Vision for Process AutomationBased in Aalen, Baden-Württemberg hema designs customer-spe-

cifi c camera systems for a wide range of applications. Automated

processes and equipment warning systems depend on reliable vi-

sion systems, and with that in mind, hema electronic has designed

the seelectorICAM HO1 camera system for the mining industry. A

robust design, high dynamic range and superior quality video were

integrated during the development. An ethernet interface allows the

digital camera to be easily installed in digital networks.

A unique feature of the seelectorICAM HO1 is the high-dynamic

range video imaging. A more than 120-dB dynamic range combined

with a high-quality color image of 1.3 megapixel exceeds what is

available in existing systems. The plant manager or equipment op-

erator can now see and detect people and obstacles next to fl ood-

lights even in dark areas.

Reliable detection has taken on an added importance as more

mining operations consider autonomous operations. With this type

of camera installed, remotely operating machines and the use

of unmanned aerial vehicles (UAVs) is within reach. Not only for

proof of concept, but also for safety and security in deep mining

operations. All the systems already in use could benefi t from these

camera options.

The robust electronics and the IP67 housing ensure a safe op-

eration. The reliable optics and cabling complete the system. The

camera adapts easily to existing digital networks using standard-

ized digital interfaces such as Ethernet or wireless connections.

The new camera has been tested on construction machines.

It was used in rear-view camera applications on excavators

and wheel loaders. The results show the exquisite image quali-

ty. The system was then tested on rear-view mirror applications.

Operators reported good results even at sunset. Now hema

hopes to test the seelectorICAM HO1 in mining and material

handling applications. These modern cameras with HDR sensor

technology could add another layer of safety and security to ex-

isting operations.

hema has designed a robust camera for mining operations.

The DMT Pilot 3-D navigates without GPS.



http://www.abelpumps.com

http://www.the-miningforum.com


PFREUNDT GmbH | Robert-Bosch-Str. 5 | 46354 Südlohn | [email protected]

www.pfreundt.de | Phone +49 (0) 28 62 / 98 07-0

Weighing system solutions ‚Made in Germany‘

Precision is our passion.

Weighing system solutions

WK60

Linear Booster Drives for ConveyorsLast year, the Prosper-Haniel coal mine installed a TT Drive on its

H2 belt conveyor without interrupting operations, achieving a com-

prehensive solution. A subsequent installation of another TT Drive

resulted in further cost reductions for the mining company.

Owned by RAG Deutsche Steinkohle, Prosper-Haniel produces

about 3 million metric tons (mt) of coal per year. The H2 conveyor

transports raw coal 1,270 m with a lift of 186 vertical m. Its operat-

ing speed amounts to 3.2 m/s with a capacity of 2,000 mt/h.

With the installation of the first TT Drive, Voith made it possible

for the Prosper-Haniel mine to carry on using a heavily damaged

steel cord belt (ST5000) until the next scheduled downtime and pre-

vented an unplanned shutdown and corresponding production loss.

During the next downtime, Voith installed a second TT Drive in the

H2 conveyor. This reduced more belt tension and Prosper-Haniel has

since been able to operate the conveyor with a cost-saving fabric

belt (PVG2000/1).

Project managers Ralf Dohle and Wolfgang Kosiuk from RAG

Deutsche Steinkohle are completely satisfied with the booster

drives and the project execution. “Voith’s solution has provided

us with a dual benefit,” Dohle said. “Not only did we manage to

avoid an unplanned shutdown because of the damaged belt, we

are now able to use a textile belt instead of an expensive steel

cord belt for the system.”

The Voith TurboBelt TT Linear Booster Drive is a high-perfor-

mance secondary drive for belt conveyors. It extends the use of belts

in existing systems and increases their available power. In new belt

conveyor systems, it reduces the requirements on belt quality, lead-

ing to considerable cost savings.

Dynamic Weighing SystemsWhen it comes to mobile weighing systems, Pfreundt continues

to improve its product line for wheel loaders, and they have some

great ideas for mining applications as well. The company is one of

the leading international producers of integrated weighing systems

with 40 agencies worldwide.

The actual weighing system WK60 has been available for about

two years now. “Improvements in technology and materials have

allowed us to develop the WK60 and the user interface looks a lot

like an iPad, except that it’s 6-cm thick,” said Bruno Reckmann,

director of sales and marketing for Pfreundt. The back of the device

is equipped with a plug-and-play connection simplifying the instal-

lation. “A technician needs to calibrate the system, but it’s relatively

simple to assemble and install,” Reckmann said. “The electrical

connections on its predecessor, the WK50, were much more compli-

cated with different plugs and cables. Now the cable ends attach to

color-coded positions.” The system calculates the load in the bucket

based on hydraulic pressure and the bucket lift.

“The WK60 operates well within the hydraulic limits of large

wheel loaders used in open-pit mining operations as well as the

large LHDs found underground. Because they only have 30 cm to

50 cm of lift, LHDs presented a problem at first. But now we have

The Voith TurboBelt TT Linear Booster Drive allowed RAG to replace a steel cord belt with a cost-saving fabric belt.


http://www.pfreundt.de


www.erlau.com Erlau AG | Erlau 16, 73431 Aalen, Germany | Tel +49 7361 595-0

ERLAU TYRE PROTECTION CHAINSPower of steel plus passion of man for advanced asset protection.

•Reducing your operating costs•Lowering your downtime•Increasing your productivity

resolved those issues and the system

works very well,” Reckmann said.

Pfreundt recently announced some

improvements to its WK60 electronic

weighing system, which will play an

integral role in its “Speed Weigh Tech-

nology” for wheel loaders. This form

of dynamic weighing allows a weight

determination without disrupting the

production process. Technology improve-

ments have extended the measurement

range to the point where the system

can get an exact weight indication with

a minimal bucket height, which could

prove useful underground.

In April, Pfreundt will unveil the

WK60-XS, which will have an even

smaller display, 5 in. compared to the

7 in. “This is important for confined

operator cabins such as those found in

mining,” Reckmann said. Pfreundt will

present this new weighing system for

the first time at Conexpo in Las Vegas

in March. The display for the WK60 mobile weighing system looks a lot like today’s tablets.

http://www.erlau.com


GERMAN VENDOR MATRIX

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Special equipment for open pits

Dewatering (underground & open pit)

Blasting equipment

Conveying & haulage underground

Shaft winding equipment

Winches & hoists

Trackless underground vehicles

Preparation plants

Crushers & millsSizing equipment

Sorting equipment

Dewatering, proportioning, m

ixing eq.

Briquetting & granulation equipment

Dedusting, water treatment

Dewatering plant

Coke oven plant equipment

Continuous conveyor & components

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Ventilation & air-c

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uck/shovel)



Blasting equipment



Winches & hoists


Preparation plants


Sorting equipment


ixing eq.



Dewatering plant




Stockpile equipment

Driving aggregates

Control equipment





Software



SAM

SON

Sand

vik

Cru

shin

g Te

chno

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logi

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Sche

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lte

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thau

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SIEM

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ecbe

rg

Siem

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Scha

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STEI

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TAKR

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Thom

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thys

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ustr

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olut

ions

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TML

Tech

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VULK

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WIL

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Shaft sinking

Deep well drill

ing equipment



roadways

Extractio

n (longwall)

Extractio

n (vein, room & pilla

r mining)

Ventilatio

n & air-conditio

ning

Stowing Extractio

n in open pits (contin

uous)

Extractio

n in open pits (truck/shovel)

Special equipment for o

pen pits

Dewatering (u

nderground & open pit)

Blasting equipment



Winches & hoists


Preparation plants

Crushers & mills

Sizing equipment

Sorting equipment

Dewatering, proportio

ning, mixing eq.

Briquettin

g & granulation equipment

Dedusting, w

ater treatm

ent

Dewatering plant


Continuous conveyor &

components


Stockpile equipment

Driving aggregates

Control equipment

Power supply

Communication, navigatio

n

Pneumatic & hydraulic to

ols

Compressors Accessories, w

ear parts

Mine safety Services Consulting/Engineerin

g

Software


ABB Automation GmbH

Geschäftsbereich Open Pit Mining

Hänchener Str. 14

3050 Cottbus

Web: www.abb.com/mining

ABEL GmbH

Abel-Twiete 1

21514 Büchen

Web: www.abel.de

AEM - Anhaltische

Elektromotorenwerk Dessau GmbH

Daheimstr. 18

06842 Dessau-Rosslau

Web: www.aemdessau.de

AIR LIQUIDE GLOBAL E&C SOLUTIONS

Germany GmbH

Olof-Palme-Straße 35

60439 Frankfurt

Web: www.engineering-solutions.

airliquide.com

Alimak Hek GmbH

Frauenbrunner Str. 25

75031 Eppingen

Web: www.alimakhek.de

allmineral Aufbereitungstechnik

GmbH & Co KG

Baumstr. 45

47198 Duisburg

Web: www.allmineral.com

ANDRITZ Ritz GmbH

Güglingstr. 50

73529 Schwäbisch Gmünd

Web: www.andritz.com

Andritz Separation GmbH

Dillenburger Str. 100

51105 Köln

Web: www.andritz.com

apc analytics GmbH

Daimlerstrasse 17

61449 Steinbach / Ts.

Web: www.apc-analytics.com

Atlas Copco MCT GmbH

Langemarckstr. 35

45141 Essen

Web: www.atlascopco.de

AUMUND Fördertechnik GmbH

Saalhoffer Str. 17

47495 Rheinberg

Web: www.aumund.com

AViTEQ Vibrationstechnik GmbH

Im Gotthelf 16

65795 Hattersheim

Web: www.aviteq.de

BARTEC Sicherheits- und

Schaltanlagen GmbH

Holzener Str. 35 - 37

58708 Menden

Web: www.bartec-mining.com

Bauer Maschinen GmbH

BAUER-Str. 1

86529 Schrobenhausen

Web: www.bauer.de

Becker Mining Systems AG

Walter-Becker-Straße 1

66299 Friedrichsthal

Web: www.becker-mining.com

Bell Equipment (Deutschland) GmbH

Willy-Brandt-Straße 4-6

36304 Alsfeld

Web: www.bellequipment.de

BEUMER Group GmbH & Co KG

Oelder Str. 40

59269 Beckum

Web: www.beumergroup.com

BHS-Sonthofen GmbH

An der Eisenschmelze 47

87527 Sonthofen

Web: www.bhs-sonthofen.com

http://www.abb.com/mining

http://www.abel.de

http://www.aemdessau.de

http://airliquide.com

http://www.alimakhek.de

http://www.allmineral.com

http://www.andritz.com

http://www.andritz.com

http://www.apc-analytics.com

http://www.atlascopco.de

http://www.aumund.com

http://www.aviteq.de

http://www.bartec-mining.com

http://www.bauer.de

http://www.becker-mining.com

http://www.bellequipment.de

http://www.beumergroup.com

http://www.bhs-sonthofen.com


BOCHUMER EISENHÜTTEHEINTZMANN GMBH & CO KGKlosterstr. 46

44787 Bochum

Web: www.be-heico.de

Bosch Rexroth AG Maria-Theresien-Str. 23

97816 Lohr am Main

Web: www.boschrexroth.com

BRÄUTIGAM Gear & Mining Tech GmbH & Co KGAm Schürmannshütt 8 - 18

47441 Moers

Web: www.braeutigam-group.com

CATERPILLAR Global MiningEurope GmbHIndustriestr. 1

44534 Lünen

Web: www.cat.com/mining

CATERPILLAR Global MiningHMS GmbHKarl-Funke-Str. 36

44149 Dortmund

Web: www.mining.cat.com

CFT GmbHCompact Filter Technic

Beisenstr. 39 - 41

45964 Gladbeck

Web: www.cft-gmbh.de

CIV Präzisionstechnik GmbHTuchmacherweg 11

39288 Burg

Web: www.civ-burg.de

Coal ControlGesellschaft für Automation mbHReisholzstr. 15

40721 Hilden

Web: www.coal-control.com

Cyrus GmbH SchwingtechnikAm Stadion 40

45659 Recklinghausen

Web: www.cyrus-germany.com

Deilmann-Haniel Mining Systems GmbHHaustenbecke 1

44319 Dortmund

Web: www.dhms.com

DEUTZ AGOttostr. 1

51149 Köln

Web: www.deutz.com

DMT GmbH & Co KGAm Technologiepark 1

45307 Essen

Web: www.dmt-group.com

Maschinenfabrik Heinrich Döpke GmbHStellmacherstr. 10

26506 Norden

Web: www.doepke-gmbh.de

Dräger Safety AG & Co KGaARevalstr. 1

23560 Lübeck

Web: www.draeger.com

DÜCHTING PUMPENMaschinenfabrik GmbH & Co KGWilhelm-Düchting-Str. 22

58453 Witten

Web: www.duechting.com

DURUM Verschleißschutz GmbHCarl-Friedrich-Benz-Str. 7

47877 Willich

Web: www.durmat.com

EEP Elektro-Elektronik Pranjic GmbHAm Luftschacht 21

45886 Gelsenkirchen

Web: www.eep.de

Eickhoff Bergbautechnik GmbHAm Eickhoffpark 1

44789 Bochum

Web: www.eickhoff-international.com

http://www.be-heico.de

http://www.boschrexroth.com

http://www.braeutigam-group.com

http://www.cat.com/mining

http://www.mining.cat.com

http://www.cft-gmbh.de

http://www.civ-burg.de

http://www.coal-control.com

http://www.cyrus-germany.com

http://www.dhms.com

http://www.deutz.com

http://www.dmt-group.com

http://www.doepke-gmbh.de

http://www.draeger.com

http://www.duechting.com

http://www.durmat.com

http://www.eep.de

http://www.eickhoff-international.com


Maschinenfabrik Gustav Eirich

GmbH & Co KG

Walldürner Str. 5074736 HardheimWeb: www.eirich.com

EnviroChemie GmbH

In den Leppsteinswiesen 964380 RossdorfWeb: www.envirochemie.com

ESI ITI GmbH

Schweriner Str. 101067 DresdenWeb: www.itisim.com

FAM Förderanlagen Magdeburg

und Baumaschinen GmbH

Sudenburger Wuhne 4739112 MagdeburgWeb: www.fam.de

FELUWA Pumpen GmbH

Beulertweg 1054570 MürlenbachWeb: www.feluwa.com

Filtration Group GmbH

(Formerly MAHLE Industrial Filtration)Schleifbachweg 4574613 ÖhringenWeb: www.filtrationgroup.com

FLSmidth Wadgassen GmbH

Karl-Koch-Str. 166787 WadgassenWeb: www.flsmidth.com

FLSmidth Wiesbaden GmbH

Am Klingenweg 4a65396 WallufWeb: www.flsmidth.com

GEA Westfalia Separator Group

Werner-Habig-Str. 159302 OeldeWeb: www.westfalia-separator.com

Getriebebau Nord GmbH & Co KG

Getriebebau-Nord-Str. 122941 BargteheideWeb: www.nord.com

GHH Fahrzeuge GmbH

Emscherstr. 5345891 GelsenkirchenWeb: www.ghh-fahrzeuge.de

Gothe & Co GmbH

El.-Ap. Elektro-ApparateKruppstr. 19645472 Mülheim an der RuhrWeb: www.gothe.de

GreCon Greten GmbH & Co KG

Hannoversche Straße 5831061 AlfeldWeb: www.grecon.com

GTA Maschinensysteme GmbH

Loikumer Rott 2346499 HamminkelnWeb: www.gta.eu

H + E Logistik GmbH

Josef-Baumann-Str. 1844805 BochumWeb: www.helogistik.de

H. C. Starck Tungsten GmbH

Landsberger Str. 9880339 MünchenWeb: www.hcstarck.com

HADEF HEINRICH DE FRIES GmbH

HebezeugfabrikGauss Str. 2040235 DüsseldorfWeb: www.hadef.de

Hammelmann GmbH

Carl-Zeiss-Straße 6-859302 OeldeWeb: www.hammelmann.com

http://www.eirich.com

http://www.envirochemie.com

http://www.itisim.com

http://www.fam.de

http://www.feluwa.com

http://www.filtrationgroup.com

http://www.flsmidth.com

http://www.flsmidth.com

http://www.westfalia-separator.com

http://www.nord.com

http://www.ghh-fahrzeuge.de

http://www.gothe.de

http://www.grecon.com

http://www.gta.eu

http://www.helogistik.de

http://www.hcstarck.com

http://www.hadef.de

http://www.hammelmann.com


Hauhinco MaschinenfabrikGmbH & Co KGBeisenbruchstr. 10

45549 Sprockhövel

Web: www.hauhinco.de

HAVER NIAGARA GmbHRobert-Bosch-Str. 6

48153 Münster

Web: www.haverniagara.com

HAWE Hydraulik SEStreitfeldstr. 25

81673 München

Web: www.hawe.de

HAZEMAG MiningBrokweg 75

48249 Dülmen

Web: www.mining.hazemag-group.com

hema electronic GmbHRöntgenstraße 31

73431 Aalen

Web: www.hema.de

Herrenknecht AGSchlehenweg 2

77963 Schwanau

Web: www.herrenknecht.com

HYDAC INTERNATIONAL GmbHIndustriegebiet

66280 Sulzbach/Saar

Web: www.hydac.com

Ingeteam GmbHHerzog-Heinrich-Str. 10

80336 München

Web: www.ingeteam.com

JÖST GmbH + Co KGGewerbestr. 28 - 32

48249 Dülmen

Web: www.joest.com

KAMAT GmbH & Co KGSalinger Feld 10

58454 Witten

Web: www.kamat.de

Kleemann GmbHManfred-Wörner-Straße 160

73037 Göppingen

Web: www.kleemann.info

Komatsu Germany GmbHBuscherhofstr. 10

40599 Düsseldorf

Web: www.komatsu-mining.de

Maschinenfabrik KÖPPERNGmbH & Co KGKönigsteiner Str. 2

45529 Hattingen

Web: www.koeppern.com

Krummenauer GmbH & Co KGWellesweilerstr. 95

66538 Neunkirchen

Web: www.krummenauer.de

KSB AktiengesellschaftPumpen & Anwendungen FeststofftransportJohann-Klein-Str. 9

67227 Frankenthal

Web: www.ksb.com

KVT Kurlbaum AGSachsenring 4-6

27711 Osterholz-Scharmbeck

Web: www.kvt-group.de

Liebherr-Mining Equipment SAS49 rue Frédéric Hartmann

68025 Colmar, France

Web: www.liebherr.com

http://www.hauhinco.de

http://www.haverniagara.com

http://www.hawe.de

http://www.mining.hazemag-group.com

http://www.hema.de

http://www.herrenknecht.com

http://www.hydac.com

http://www.ingeteam.com

http://www.joest.com

http://www.kamat.de

http://www.kleemann.info

http://www.komatsu-mining.de

http://www.koeppern.com

http://www.krummenauer.de

http://www.ksb.com

http://www.kvt-group.de

http://www.liebherr.com


LOESCHE GmbH

Hansaallee 243

40549 Düsseldorf

Web: www.loesche.com

marco Systemanalyse und

Entwicklung GmbH

Hans-Böckler-Str. 2

85221 Dachau

Web: www.marco.de

MATO GmbH & Co KG

Benzstr. 16 - 24

63165 Mühlheim

Web: www.mato.de

MBE Coal & Minerals

Technology GmbH

Gottfried-Hagen-Str. 20

51105 Köln

Web: www.mbe-cmt.com

MESUTRONIC Gerätebau GmbH

Hackenfeld 13

94259 Kirchberg

Web: www.mesutronic.de

MTU Friedrichshafen GmbH

Maybachplatz 1

88045 Friedrichshafen

Web: www.mtu-online.com

J. D. NEUHAUS GmbH & Co KG

Windenstr. 2 - 4

58455 Witten

Web: www.jdngroup.com

Nilos GmbH & Co KG

Reisholzstr. 15

40721 Hilden

Web: www.nilos.com

oddesse Pumpen- und

Motorenfabrik GmbH

Am Pappelwald 12

39387 Oschersleben

Web: www.oddesse.de

Hermann Paus Maschinenfabrik GmbH

Siemensstr. 1 - 9

48488 Emsbüren

Web: www.paus.de

PFISTER WAAGEN BILANCIAI GMBH

Linker Kreuthweg 9

86444 Affing-Mühlhausen

Web: www.pfisterwaagen.de

PFREUNDT GmbH

Robert-Bosch-Str. 5

46354 Südlohn

Web: www.pfreundt.de

PLAKOMA GmbH

Bahnhofstr. 101

66809 Nalbach-Körprich

Web: www.plakoma.de

PLARAD Maschinenfabrik Wagner

GmbH & Co KG

Birrenbachshöhe 17

53804 Much

Web: www.plarad.de

PRAKLA Bohrtechnik GmbH

Moorbeerenweg 3

31228 Peine

Web: www.prakla.de

WOLFGANG PREINFALK GMBH

Im Oberen Werk 4

66386 St. Ingbert

Web: www.preinfalk.de

Pumpentechnik Erkrath

GmbH + Co KG

Max-Planck-Str. 28

40699 Erkrath

Web: www.pumpentechnik-erkrath.de

Putzmeister Solid Pumps GmbH

Max-Eyth.Str. 10

72631 Aichtal

Web: www.pmsolid.com

http://www.loesche.com

http://www.marco.de

http://www.mato.de

http://www.mbe-cmt.com

http://www.mesutronic.de

http://www.mtu-online.com

http://www.jdngroup.com

http://www.nilos.com

http://www.oddesse.de

http://www.paus.de

http://www.pfisterwaagen.de

http://www.pfreundt.de

http://www.plakoma.de

http://www.plarad.de

http://www.prakla.de

http://www.preinfalk.de

http://www.pumpentechnik-erkrath.de

http://www.pmsolid.com


RWE Technology International GmbH

Huyssenallee 12-14

45128 Essen

Web: www.rwepi.com

SAMSON AG

MESS- UND REGELTECHNIK

Weismüllerstr. 3

60314 Frankfurt

www.samson.de

Sandvik Mining & Construction

Crushing Technology GmbH

Technologie Park Bergisch Gladbach

Friedrich-Ebert-Str. 75

51429 Bergisch Gladbach

Web: www.sandvik.com

SCHADE Lagertechnik GmbH

Bruchstraße 1

45883 Gelsenkirchen

Web: www.schade-lagertechnik.com

Schaeffler Technologies AG & Co KG

Georg-Schäfer-Straße 30

97421 Schweinfurt

Web: www.schaeffler.de/

rohstoffgewinnung_verarbeitung

Schalker Eisenhütte

Maschinenfabrik GmbH

Am Eickhoffpark 1

44789 Bochum

Web: www.schalke.eu

Schenck Process Europe GmbH

Pallaswiesenstraße 100

64293 Darmstadt

Web: www.schenckprocess.com

Schopf Maschinenbau GmbH

Parkstr. 19 - 21

73760 Ostfildern

Web: www.schopf-mining.com

F. E. Schulte Strathaus GmbH & Co KG

Fördertechnik - Dichtungssysteme

Runtestr. 42

59457 Werl

Web: www.schulte-strathaus.de

SEKA Schutzbelüftung GmbH

Im Höger 4 a

76829 Landau

Web: www.schutzbelueftung.de

SIEMAG TECBERG GmbH

Kalteiche-Ring 28-32

35708 Haiger

Web: www.siemag-tecberg.com

Siemens AG

Process Industries and Drives Division

Schuhstr. 60

91052 Erlangen

Web: www.siemens.com/mining

SMT Scharf GmbH

Römerstr. 104

59075 Hamm

Web: www.smtscharf.com

STEINERT Elektromagnetbau GmbH

Widdersdorfer Str. 329 - 331

50933 Köln

Web: www.steinert.de

GKN Stromag AG

Hansastr. 120

59425 Unna

Web: www.stromag.com

TAKRAF GmbH

Torgauer Str. 336

04347 Leipzig

Web: www.takraf.com

Thomas Magnete GmbH

San Fernando 35

57562 Herdorf

Web: www.thomas.magnete.com

http://www.rwepi.com

http://www.samson.de

http://www.sandvik.com

http://www.schade-lagertechnik.com

http://www.schaeffer.de/

http://www.schalke.eu

http://www.schenckprocess.com

http://www.schopf-mining.com

http://www.schulte-strathaus.de

http://www.schutzbelueftung.de

http://www.siemag-tecberg.com

http://www.siemens.com/mining

http://www.smtscharf.com

http://www.steinert.de

http://www.stromag.com

http://www.takraf.com

http://www.thomas.magnete.com


thyssenkrupp Industrial Solutions AG

thyssenkrupp Allee 1

45143 Essen

Web: www.thyssenkrupp-industrial-

solutions.com

TLT-Turbo GmbH

Gleiwitzstr. 7

66482 Zweibrücken

Web: www.tlt-turbo.com

TML Technik GmbH

Daimlerstr. 14 - 16

40789 Monheim

Web: www.tml-technik.com

Tüschen & Zimmermann

GmbH & Co KG

Winterberger Str. 82

57368 Lennestadt

Web: www.tueschen-zimmermann.de

URACA GmbH & Co KG

Sirchinger Str. 15

72574 Bad Urach

Web: www.uraca.de

VELCO Gesellschaft für Förder-

Spritz- und Siloanlagen mbH

Haberstr. 40

42551 Velbert

Web: www.velco.de

Voith Turbo GmbH & Co KG

Voithstr. 1

74564 Crailsheim

Web: www.voith.com

VULKAN Kupplungs- und Getriebebau

Bernhard Hackforth GmbH & Co KG

Heerstr. 66

44634 Herne

Web: www.vulkan.com

WELLER Pumpen GmbH

Westicker Str. 44 - 46

59174 Kamen

Web: www.weller-pumpen.de

WILO SE

Nortkirchenstr. 100

44263 Dortmund

Web: www.wib.com

WIRTGEN GmbH

Reinhard-Wirtgen-Str. 2

53578 Windhagen

Web: www.wirtgen.de

ABB Automation GmbH.....................................................VDMA IBC

ABEL GmbH & Co KG ......................................................... VDMA 35

Beumer Group GmbH & Co KG ............................................. VDMA 5

Draegerwerk AG & Co KG a.A. ............................................ VDMA 17

Eickhoff Bergbautechnik GmbH......................... VDMA 21, VDMA 23

Erlau AG ............................................................................ VDMA 37

Hermann Paus Maschinenfabrik GmbH............................. VDMA 24

KAMAT Pumpen GmbH & Co KG .........................................VDMA BC

Maschinenfabrik Koeppern GmbH & Co KG........................ VDMA 27

Liebherr Holding GmbH ....................................................... VDMA 7

Longwall USA 2017 ........................................................... VDMA 31

Mining Forum (DMT).......................................................... VDMA 29

MTU Friedrichshafen GmbH............................................... VDMA 13

Pfreundt GmbH.................................................................. VDMA 36

RWE Power International GmbH........................................... VDMA 9

Siemag Tecberg GmbH ...................................................... VDMA 19

Siemens AG International.................................................... VDMA 3

Takraf GmbH .................................................................... VDMA IFC

Wirtgen GmbH................................................................... VDMA 11

ADVERTISING INDEX

http://solutions.com

http://www.tlt-turbo.com

http://www.tml-technik.com

http://www.tueschen-zimmermann.de

http://www.uraca.de

http://www.velco.de

http://www.voith.com

http://www.vulkan.com

http://www.weller-pumpen.de

http://www.wib.com

http://www.wirtgen.de

—

Let’s write the future.

Greater transport capacity

with increased reliability.

Conveyors need to cover longer distances and ascend steeper gradients

in increasingly remote locations and harsher environments. The result is

ever more stressed and less maintained equipment which leads to additional

sources of error. To increase reliability, ABB developed a streamlined solution

which helps to overcome the mechanical limitations of the gearbox.

The new gearless conveyor drive (GCD) with a permanent magnet (PM) motor

delivers up to 50% more reliability and improves energy efficiency. In addition

to the eliminated gearbox, the PM torque motor can work without a complex

external cooling system, which avoids further system errors. For more

information, please visit us at www.abb.com/mining

http://www.abb.com/mining

KAMAT GmbH & Co. KG . Salinger Feld 10 . 58454 Witten . Germany

Phone: +49 2302 8903-0 . Fax: +49 2302 801917 . Mail: [email protected] . www.KAMAT.de

Smooth operation at bigger flows

Product data Parameters

1185 l/min (max) at 350 bar Fluid Viscosity < 2000 mPas

763 l/min (typ) at 360 bar Input power 800 kW (max)

up to 641 l/min at 430 bar (max)

without boosterpressure

Operating Pressure 3500 bar (max)

HIGH PRESSURE

PLUNGER PUMPS

AND SYSTEMS

LESS IS

MOREWhere others need more pumps, we simply use bigger ones.

Our 5-plunger-pumps provide power - up to 800 kW.

When using a variable speed drive, the range of

adjustment is between 10 % to 100 %.

Your advantages: less pumps, less service, longer lifetime

and higher availability, energy savings. Plus: only one of the

pumps in the system needs to be run by a variable speed drive.

THIS REDUCES YOUR CAPITAL INVESTMENT.

< 2000 mPas

800 kW (max)

3500 bar (max)

HIGH PRESSURE

PLUNGER PUMPS

Your advantages: less pumps, less service, longer lifetime

and higher availability, energy savings. Plus: only one of the

pumps in the system needs to be run by a variable speed drive.

THIS REDUCES YOUR CAPITAL INVESTMENT.

est of ermany mining equipment 2017 · takraf gmbh torgauer straße 336 04347 leipzig, germany...

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