INDIA 2018

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 21 2018 • VDMA MINING SUPPLEMENT What sets SIEMAG TECBERG apart for others is its detailed engi- neering and design work, and its ability to fabricate large systems. Over the last 10 years, the engineering team has used modern fi- nite element analysis systems to improve existing designs and to produce new drum technologies. The company has its own types of specially designed slide bearings, types of brake elements and ap- proved electrohydraulic braking systems with deceleration controls. "We are only one of a very few companies in the world with the abil- ity to deliver such types of large hoisting sytsmems," Krenzer said. "And, the 90-ton main shaft for the Norilsk Nickel double-drum Blair hoist is the largest hoist shaft we have ever supplied." From a mining engineering perspective, Norilsk Nickels's SKS1 project will be a major shaft-hoisting achievement. Designing a Koepe system that will hoist 2 km in a single lift is a feat unto itself. In addition to the 90-ton main shaft, SIEMAG TECBERG will also ship about 3,000 tons of equipment to the mine site and they will charter a vessel to transport the two shaft-hoisting kits with service auxiliaries form Germany to Russia. "This is a very big, exciting project for us with a lot of firsts," Krenzer said. "For many years, Norilsk Nickel has relied on our equip- ment, but now they have asked us to supply complete service and production hoisting systems with a defined yearly output." Throughout its history, which began in a blacksmith shop in 1871, SIEMAG TECBERG has always focused on quality craftsman- ship and has never shied away from major projects. Today that tra- dition continues as the company broadens its scope from a compo- nent supplier to a systems provider. Water-based Hydraulic Solutions The Hauhinco name is synonymous with water-hydraulic systems for longwall mining, and they have evolved with mining markets. In 1981, they established a subsidiary close to Pittsburgh to service a growing longwall business in the USA. Today, they have mining and industrial partners around the world. "Wherever there is a longwall market, you will find Hauhinco," said Holger Hoffmann, general manager. "We are the leading supplier for high-pressure water hydraulic applications and we are developing new solutions here in Germany." The Hauhinco production facilities in Sprockhövel look much different today than they did 110 years ago. At peak times, 300 employees were building Pickaxes and rock drills to support not only the local miners extracting coal in the Ruhr Valley, but also to mines in neighboring countries. Today, the company's engineers and factory workers have the same level of commitment to quality man- ufacturing, but they have more sophisticated tools and they supply equipment and solutions worldwide. "We have made a significant investment in our manufacturing and testing machinery during the last three years," said Christopher Durst, strategic marketing man- ager, Hauhinco. "Tolerances today are tight and to meet production standards, we need to use the most modern equipment." Training, quality control, and research and development are three areas where the company is committed to excellence, Hoffmann explained. Hauhinco not only has an apprentice program to train its own employees, but they also have a training center for their custom- ers. They have a shield sitting on the factory floor next to a classroom where instructors can teach both theory and offer hands-on training. Hauhinco is certified according to DIN EN ISO 9001-2015. "Each system is tested and receives a certificate before it leaves this fac- tory," Hoffmann said. "We want to make sure everything works as planned. The last thing we want is for a mine in Australia to take a pump or a valve underground only to find it does not work." When asked how often pumps are rejected once they reach the test bench, Hoffmann said, "Rejected? Never. The quality is moni- tored throughout the entire production process. If there is problem, it is rejected earlier in the chain. Once it reaches this test bench, it's an ISO-certified product." "Ruhrkohle AG has Hauhinco pumps that have run for more than 30 years without a problem," Hoffmann said. "We come from the underground mining sector and deliver products to the industrial sector, while most of our competitors come from the industrial sector and now also supply to underground mines." Hauhinco offers seven models for the mining business that range from the EHP-3K 75 to the EHP-5K 400, which would be five plungers, 400 kilowatts, 725 m 3 /min and 500 bar pressure. "The EHP-5K 400 is currently our largest pump and it is becoming very popular with the longwall mines," Durst said. "We have installed them in Russia, China and the USA." The pressure requirements in underground longwall mining have changed. "The new Russian longwalls need the power," Hoff- mann said. "Some Russian longwalls have as many as four or five 5K 400s for a single face." The company is modifying existing pumps and also developing entirely new plunger pumps and systems. "We have also improved the condition monitoring system," Hoffmann said. "Normally, we measure temperature, pressure and energy consumption. Now we can also measure vibration, which allows users to see problems de- veloping." Hauhinco has supplied more than 1,000 systems world- wide and it keeps $6 million in parts for pumps and valves in stock. They have air freight area ready to ship pumps, valves and spare parts anywhere at moment's notice. Six years ago, Hauhinco started to develop water treatment systems for underground mining. With this system, the company reacted to the concerns of mines and OEMs on the possible effects bad water quality can have on the entire longwall equipment. "We are working with water as a hydraulic medium and it's important to have a clean medium," Durst said. "Longwalls are a high capital expense and coal companies want to make sure that they operate for a long time. Water is the blood of the system and it must be clean." A hydrocyclone filters solids from the water before it enters a three-step filtration process with a fineness-of-filtration of 100 microns (µm), 50 µm and 25 µm, and an automatic backwash. A 50-µm bag filter clarifies the returning water-HFA-emulsion from the longwall face. The water treatment system filters the impurities. Hauhinco asks the mine for a water quality analysis and they cus- tom design a treatment system to filter the water. "Miners are much more in tune with water quality," Hoffmann said. "Customers on the industrial side often take water quality for granted." The standard system converts 2,000 liters per hour (l/h) of water with a conduc- tivity of 1,990 micro-Siemens (µS) to 1,000 l/h of clean water with Hauhinco's water treatment system produces 1,000 l/h clean and salt-free water. The conductivity of the water is approximately 20 µS after the treatment process and nearly salt-free.

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