Best of Germany 2014 - Mining Equipment and Mining Technology

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34 VDMA 2016 • VDMA MINING SUPPLEMENT Today, almost every mine is evaluating at least the option of adding a fully or semimobile crushing system to reduce truck haulage by 50% or maybe even to zero, Jabs explained. "When you consider all of different factors, such as labor costs, CO 2 emissions and safety is- sues, miners have realized the value in reducing the haul distance," Jabs said. "With the amount of diesel fuel, tires and engines being handled, some operations look more like storage tank sites and ser- vice centers than mines." If the electrical power is available, conveyors are a much more cost effective means of moving bulk materials. They can cross great distances effectively, but large inclines and declines increase the tension of the system. "The biggest risk in the past, when running an 8,000- to 10,000-mt/h conveyor uphill, was the gear set," Pa- pajewski said. "It was the critical link that was failing more often in high-horsepower applications and gearless drives eliminate that risk." Already several of the new large mining operations coming online in Latin America have installed long gearless conveyor drives with thyssenkrupp's help. The company is now looking to make a similar leap with steep angle conveying. Peter Börsting, thyssenkrupp's R&D coordi- nator for technology and innovation in mining, discussed the company's inclined conveyor concepts. "Three years ago, we unveiled an incline conveyor with two skips running on steel structure mounted to the slope of the pit wall," Börsting said. "We have now taken that a step further, attaching the system to a rope structure. It lowers the capacity a bit, but the system is now independent from the slope wall at the pit bottom, allowing a smooth transition to the loading point. This is a more balanced, energy-efficient system. The stability of the slope wall is no lon- ger an issue—an important factor for areas prone to seismic ac- tivity—and it can follow the pit if it goes deeper." Many mines are evaluating steep angle conveyors. These skip systems can climb 65° to 70°, Börsting explained, while the high- est angle for a conventional conveyor is 15°-18° depending on the materials. "Our colleagues in the materials handling division have the cable and crane technology and we knew we could apply it to open-pit mining," Börsting said. Thyssenkrupp has three high-angle conveying systems: the skip-way system for medium and large mines; the integrated skip conveyor for large capacity and high lifts; and the MegaPipe Con- veyor, which closes the inclination gap between the conventional and the skip conveyors. The MegaPipe was co-developed between thyssenkrupp, Contitech and Siemens. "We are working on other alternatives as well," Börsting said. "Steep angle conveying is going to happen and it will be a game changer." Looking toward the future, Papajewski said thyssenkrupp is look- ing at applications for Big Data. "There is a huge amount of data and, when you understand all the connections, it can be used to make improvements in efficiency," Papajewski said. As an example, Papajewski explained that all of thyssenkrupp's gyratory crushers are now being supplied with the thyssenkrupp Gy- ramatic and Telesystem. "The operators can switch it off if they like," he said. "Usually they switch it on when they need help and we can support them wherever they are in the world." "Our aim is to be as close to the client as possible not only with dealers but also with engineering," Papajewski said. "The HPGR business is a great example. We are the largest supplier and we have six large service centers to refurbish HPGRs around the world. We have huge machines to perform this maintenance and repair work, but we can also perform maintenance on crushing and grind- ing systems." This thinking ties directly to the reorganization of its business. Today, tthyssenkrupp is much more market focused. "The in- tegration of the plant business combined the strengths of market leaders and we are now capitalizing on engineering synergies," Jabs said. "The great thing about miners is they love to build these massive operations. Whether they are looking to build or improve existing opera- tions, we are ready to support them." The engineers at thyssenkrupp Industrial Solutions are looking at three steep angle conveying solutions to reduce truck haulage in open-pit mines. Efficient Drive Systems for Belt Conveyors Over the last quarter-century, most large belt conveyors operating underground in Germany have been equipped with TT linear booster drives. They offer a range of clear benefits. In new systems, the use of Voith TT Linear Booster Drives avoids transfer points, protecting the belt and resulting in a longer service life. In many cases and depending on reserves, TT drives can improve the capacity of old- er conventional conveyors—without needing to change the existing drive or replace the belt. They lower belt rating requirements and, in many cases, enable the use of textile belts in operations where, under normal conditions, a steel cord belt would be necessary. This, in turn, eases splicing, handling, and repairs, therefore reducing the run- ning cost of the overall system. The ability to operate with a lower-rated belt translates to lower running cost, as well as reduced investment in the belt—which is the single most expensive component. A few months ago Voith delivered two TT linear booster drives to the German mine, Prosper Haniel, operated by Ruhrkohle AG (RAG). The mine produces 3 million metric tons per year (mt/y) of coal. The belt con- veyor H2 is 1,270 m long and has a conveying capacity of 2,000 mt/h. The former steel-cord conveyor belt showed serious damages months

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