VDMA

Germany 2019

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 16 VDMA MINING SUPPLEMENT • 2019 Leveraging its in-house Mining Technology Center (TMTC), TAKRAF prepared conceptual and appraisal studies comparing BWEs with different mining methods. The success of a BWE ap- plication is highly related to a consistent design, according to the project conditions. This represents a crucial aspect of the compa- ny's project philosophy. BWEs have been mainly employed in lignite and coal mining operations. However, this technology has an inter- esting future in alternative areas where large amounts of material have to be (re)moved: larger-scale sand mining for construction, as well as mineral sands projects. The continuous mining method also provides an excellent opportunity for highly automated solutions. In fact, TAKRAF has developed a toolbox of operator assistance and operation planning and control features for BWE operations, based on the real-time analysis of the cutting resistance. The understanding of the instantaneous value of the cutting resistance provides invaluable information regarding the geo-mechanical properties of the native rock, state of tool wear, process efficiency, and much more. This in- formation enables the visualization and modeling of geological struc- tures, the monitoring of the wear state of cutting tools, as well as the automation of slewing speed control. The ultimate goal is to maximize production rates in compliance with stress limitations for equipment and tools. Thanks to this solution, operators can finally take advantage of the available drive capacity due to the natural heterogeneity of the rock, and the risk of overload and shutdown of the slew drives caused by local solidifications cause is minimized and/or avoided. Using similar state-of-the-art maintenance solutions, low-wear hydraulic systems for boom supports and travel control, as well as the latest variable-frequency drive technology, the availability of a giant BWE is now nearly 100%. Tailored Training Courses RWE Technology International (RWE TI) tailors OpEx-training pro- grams to meet specific customer needs, covering technical, economical and/or administrative aspects of mining and power plant operations. "The tailored training solutions are designed to grow our customers or- ganization through skilling its people and future staff," said Dr. Martin Schmid, senior mining engineer and training expert for RWE TI. "Many of these classes are facilitated in collaboration with engineers and operating staff from the RWE Group. Through sharing hands-on opera- tional knowledge, we offer genuine value to our customers." The programs that RWE offers are mainly intended for engineers, specialists, experts and middle managers, having several years of working experience. Trainees profit from the vast expertise and knowl- edge available within the RWE network, and gain valuable insights in mine operation, power plant management, operation, maintenance, health, safety and environment. Programs may include best-practice exchange with RWE peers, lectures, workshops, seminars, discussions in small groups, study visits, shadowing, case studies and mentoring. "We also take pride in ensuring participants understand how to use their new skills in practice to increase efficiency and optimize operations and production back home," Schmid said. "Therefore, training courses may range from days up to months, with flexible locations, depending on the content choice and individual training needs. Trainings may take place in Germany at RWE offices and sites, or at the mine site, depending on what is most cost-effective. We offer experienced mine experts to join participants in their daily work in-house at their company or on-site their plant site." In the case of RWE on-site trainings, the company assists its customers with necessary conditions such as accommodations, travel, and an interpreter to enable a comfortable and efficient learning environment. As far as the training course content, cus- tomers can always rely on their experts to advise on which training scheme to adopt to meet training preferences and requirements. During a typical training day, a small group (three to four people) with similar learning objectives is guided by one of RWE TI's facilitators to meet and exchange best practice with RWE operational experts during a workday. The day starts with a theoretical classroom session followed by practical site visits in the afternoon, according to carefully prepared learning schedules. To internalize the course content, RWE provides the online learning platform MOODLE for participants to summarize their lessons learned at the end of a training day. Participants are awarded with certificates, recognizing attendance and course subjects. Since 2015, RWE TI has been consulting with a major iron ore pro- ducer developing a new opencast mine. Due to the proximity of the mine site to the beautiful rainforest area, local environmental regu- lations call for the strict reduction of emissions. Truck-shovel mining methods generate significantly high emissions. So, the mine operator decided to implement an In-Pit Crushing and Conveying System (IPCC) powered by renewable energy from hydro power. RWE is well-known for its more than 120 years mine and power operator heritage, with spe- cific operator expertise in opencast mining and IPCC. In addition, RWE TI has more than 50 years of consulting history in pooling and repro- cessing RWE operator expertise from their own mine operations using this knowledge in a structured way to help other companies worldwide execute successful projects in raw material and energy production. During mid-2016, RWE TI was asked to offer a long-term workforce development program for the future mine operation, aiming to produce 90 million metric tons (mt) of iron ore annually by the end of 2020. Guiding and mentoring an open-pit mining operation in pro- duction ramp-up phase using new fully continuous mining equip- ment was the key target. The partnership began by establishing an on-site OpEx-training program to give the mining company's leadership team visibility to the operation's KPIs, including gaps between current and planned performance. So far more than 20% of the respective operation staff have been trained by RWE TI in small groups. Advanced training packages covered a variety of themes aiming to optimize the mine's organizational structure, production processes and overall performance, focusing on continuous mining, bulk material transport, shiftable belt conveyors and a technical understanding of continuous mine operation planning. Trainings took place either on the job with the equipment at the mine sites or at RWE's facilities, supplemented by classroom sessions with RWE operator staff. In addition, RWE TI embedded An RWE TI training group visits the Hambach mine during a belt shift operation with a German-Portuguese interpreter.

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