Germany 2019

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 34 VDMA MINING SUPPLEMENT • 2019 the potentially achievable improvements. BeltGenius ALEX has been developed for all conveyor systems with belts thicker than 30 mm. Depending on the conveyor length and speed, the data collection process might take between 15 and 30 minutes. The system analyzes the vertical and horizontal position of each idler. "This is the basis for belt skewing," Hutzenlaub said. "We know the real position of the idler and we can calculate what will happen when the belt is fully or partially loaded. The weight of the load impacts the steering forces. We provide a report that allows the mine to run its conveyor at the highest efficiency." The potential savings from ALEX has already been confirmed in an initial pilot run. There were significantly fewer unscheduled downtimes thanks to the sensor-based, high-precision measuring on the conveyor belt. At the same time, the energy demand for hor- izontal material transport fell by more than 10%. Following align- ment optimization, wear on the carrying idlers also decreased con- siderably, extending their lifetime by one-fifth in this case. Trough Wild Nature and Populated Regions Sichuan Yadong Cement Co. Ltd. in Pengzhou, China, has been rely- ing on a 12.5-km overland conveyor from BEUMER Group to convey limestone from their quarry to their silo. When constructed in 2009, it was the longest belt conveying system in BEUMER history (BEUM- ER installed a longer system in 2016). The troughed belt conveyor runs through hilly terrain and nature reserves, over streams and un- stable ground. The second project includes two additional overland conveyors, with an overall length of 13.7 km, transporting limestone to the cement plant. Unlike the first project, the task here was to build the conveyor across inhabited areas. Noise emission limita- tions set forth by the government also needed to be considered. A traditional Chinese proverb says that the roads in Sichuan are hard, harder than climbing to heaven. One of the cement man- ufacturers in the region is Sichuan Yadong Cement Co. Ltd. located near Chengdu. The company is a member of the Asia Cement Group, headquartered in Taipeh, Taiwan. In 2004, the Asia Cement Group decided to build a new cement plant in Sichuan. During the development phase, the company re- ceived approval from the Chinese government to use an abandoned railway to transport the limestone. Halfway through finishing the plant, however, the government decided to build a new dam. The area intended for the transport was to be flooded, which would have changed the project conditions considerably: roads would be flooded and the trucks would have to take significant detours. Asia Cement Group was also planning on building two additional kiln lines at this location. It was determined, as a time and cost-efficient alternative, to install a troughed belt conveyor able to navigate horizontal and ver- tical curves. For this, the company turned to BEUMER Group. For many years now, Asia Cement has been relying on the system supplier's ex- pertise and are currently operating several of its bucket elevators. BEUMER Group took over the mechanical and electrical engi- neering and supplied the core components for the overland con- veyor and monitored and commissioned its installation. The advan- tage: The Chinese subsidiary BEUMER Machinery Shanghai can be reached easily and deployed quickly to site. "Our colleagues were able to work closely with the customer. They know the specific local customs, speak the language and are familiar with the particular market and customer requirements," said Dr. Andreas Echelmeyer, director of conveying and loading systems at BEUMER Group. In May 2006, Asia Cement Group awarded the contract for the 12.5-km-long system. The overland conveyor can reach a mass flow of 1,500 metric tons per hour (mt/h) and a conveying speed of 4 m/s. "Compared to other conveying solutions, the open troughed belt conveyors are suitable for higher throughputs," Echelmeyer said. "Horizontal as well as vertical curve radii are possible." They can be adapted to the specific task and topography. Using BEUMER calcu- lation programs, they can calculate the static and dynamic tractive forces of the belt during the development phase of the system. This is a prerequisite for the safe dimensioning of horizontal curves. The type of drive technology and conveyor belts needed are based on these calculations. This ensures longevity of the entire system. CIM EXPO 2019 in Montreal, Canada Booth #1122 BeltGenius ALEX from Voith uses a sensor chain to detect inaccurate alignment of belt conveyors and help generate solution suggestions. The original 12.5-km conveyor spans nature reserves and rolling hills.

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