INDIA 2016

Best of Germany 2014 - Mining Equipment and Mining Technology

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2016 • VDMA MINING SUPPLEMENT VDMA 31 Global challenges including lower commodity prices, stricter environ- mental regulations and ambitious international climate change mitiga- tion targets have put significant strain on the material handling business. Overall, the mining market has been under financial strain for some time and companies are now facing critical challenges in terms of profitability and liquidity. In order to remain a market leader within the mining sector, companies need to selectively make strategic investments to ensure long-term success. Increased efficiency and avoiding downtime is key to decreasing cost per ton and thus accelerating the return on already made investments. To reach highest levels of efficiency, the mining sector is taking a fresh look at its material handling processes and looking for cost-effective solutions that address labor intensive system interfaces or maintenance intensive equipment. In prior times, process management of mines fo- cused on partial optimization of single systems like mine planning or advanced automation solutions. Today, customers demand seamless integration of all subsystems and overall process optimization from mine to the market. Keeping in mind the difficult market conditions, ABB has developed innovations that increase efficiency such as with gearless drives for conveyors and process optimization with a combined stockyard man- agement system (SYMS). These solutions can be applied to existing systems to help material handlers get even more out of their assets. The innovative SYMS solution is a good example of how the latest technology can be leveraged to cost effectively manage bulk material movement with a relatively small investment. In order to minimize the efforts on material processing, storage and handling within the complete material flow chain, an integrated stockyard management tool is needed to build interfaces and interaction between the different levels—from order fulfillment in the ERP system down to the operation of the pile or even in the mine or plant. Starting from the core of process optimization, ABB helps mines increase efficiency by delivering reliable and nearly maintenance-free gearless conveyor drives. Nowadays, conveyors have to cover longer distances and ascend steep gradients in increasingly remote locations and harsher tempera- tures. At the same time, increased transport capacity requires wider and longer belts, which in turn need higher powered conveyor drives. The result is ever more stressed and less maintained equipment, which leads to additional sources of error. In order to improve reliability by eliminating possible sources of error, the latest trend is to drive convey- or belt systems with less transfer stations. ABB responded to this trend by developing a streamlined solution that helps to overcome the mechanical limitations of the gearbox and ensures reliability. The new gearless conveyor drive (GCD) with a permanent magnet (PM) motor delivers radically higher reliability and improved energy efficiency. In addition to the eliminated gearbox, the permanent magnet motor for the GCD can work without a complex ex- ternal cooling system, which avoids further system errors. Furthermore, the product can be easily installed in new or existing conveyor drives without complex mechanical design work. The collateral savings of maintenance and energy costs by elimi- nating equipment leads to a faster return on investment of operating assets. For example, a belt conveyor system consisting of four belts and with 12 permanent magnet motors of 1,000 kW each can save approxi- mately $5 million over a five-year period. This demonstrates clearly that the right strategic investments can lead to efficiency gains in both the long and short term. Steep-angle Conveying Solutions Lowering the cost for every ton moved is a guiding principle at thyssen- krupp Industrial Solutions. The engineering powerhouse based in Es- sen, Germany, recently completed its third gearless drive installation at the Escondida mine in Chile, and additional systems are scheduled to come online at the Las Bambas and Cuajone mines in Peru. The company is also moving forward with equipment innovations, un- veiling its largest gyratory crusher (the KB 63-130) along with other crushers and sizers for the bauma event in Munich. In addition to its plans to launch a smaller, more aggressive bucketwheel excavator (BWE) for harder formations (See Innovations, p. xx), it also has ideas on how to improve value throughout the mining chain with advanced in-pit crushing and conveying (IPCC) systems. These innovations are the results of an integration plan that be- gan in March 2014 when the company combined two of its previ- ously separate plant technology companies, Thyssen-Krupp Uhde and thyssenkrupp Resource Technologies (formerly Polysius and Fördertechnik) to form thyssenkrupp Industrial Solutions. Today this group is focusing on industry-specific solutions, and mining is very important to them. "We are supplying some key technologies for the mining busi- ness from Germany, including IPCC systems and advanced crush- ing stations along with the supporting network," said Thomas Jabs, executive vice president-mining systems for thyssenkrupp Industrial Solutions. "These gearless drive systems have proven to be bene- ficial for several large-scale mining operations. We also have some exciting R&D projects that we will roll out in the near future." The engineers at thyssenkrupp see haul trucks, and truck-shovel mining to a lesser extent, as inefficient. They would like to either shorten the haul distance or eliminate it entirely and move to contin- uous mining if possible. "In the current market, mines are not increasing capacity. They are looking to maintain current levels while trying to improve the ef- ficiency of existing systems," said Detlef Papajewski, thyssenkrupp vice president of mineral processing. "There is still a lot of room for improvement as far as efficiency, especially in the area of ore and waste haulage. Crushing systems and conveyors, especially high-angle conveyors, offer some innovative solutions." In the IPCC world, there are two types of systems: fully and semimobile. Thyssenkrupp is the only company that can supply all the components: the crusher, the crusher plant and the conveying systems. "The primary loading tool dumps directly into the fully mobile system, which is mount- ed on crawlers, essentially eliminating haul trucks," Papajewski said. "On the semimobile systems, haul trucks dump into gyratory crushers. We have supplied 30 semimobile plants in the last six to seven years. We are clearly the world market leaders." If a mine decides to install a semimobile crushing station at the onset and then 10 years later de- cides to move it, Papajewski explained, the cost is not that great. Ma T erial h andling: w here T he Cos T P er Ton r eally Ma TT ers Potential investments that help miners make the most of existing assets

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