VDMA

INDA 2017

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 22 VDMA MINING SUPPLEMENT • 2017 The safety consideration for underground miners is a top priority. With bulk commodities, such as potash and coal, both of which have faced considerable downward price pressure recently, the competitive advantage is determined on a cost per ton basis. The capital and operating costs to extract and transport ore (and coal) to the surface can be significant, especially over the course of a 20- year mine life. So, it's important to choose the right system. Similar to their counterparts on the surface, underground min- ers need more power to grow production. They are vitally interest- ed in automation and they frequently turn to technology to protect workers and reduce costs. Most of the underground mining special- ists in Germany are working to meet those needs. High-end, Shaft Hoisting in Canada Mosaic, a market leader in the fertilizer business and a potash pro- ducer, partnered with SIEMAG TECBERG to supply and install large, modern shaft hoisting equipment for its new K3 mine site located in Esterhazy, Saskatchewan. At a depth of approximately 1,100 meters (m), the K3 project consists of two shafts. It is one of the largest potash projects in Canada and is designed to hoist millions of tons per year. Production is slated for 2018. The K3 hoist tower contains two advanced technology SIEMAG TECBERG winders with supporting rope sheave assemblies. The 2011 contract for these machines was awarded by Mosaic to an international consortium of SIEMAG TECBERG Germany and Con- verteam (now GE). The order included engineering, manufacturing, delivery, erection, commissioning and post-project maintenance ser- vices. SIEMAG TECBERG Germany provided the mechanical equip- ment and used its U.S.-based office in Milwaukee for local support. The winder and sheave designs and reviews started in 2011 and continued until mid-2012. The equipment was evaluated using finite element modeling (FEM) tools and designed to comply with multiple international and local standards including Saskatchewan Mining Regulations, Canadian CSA, German TAS and consultant re- quirements similar to South African SABS. In addition, the hoist was customized to incorporate Mosaic-specific hoist experiences and "lessons learned" to maximize its efficiency and maintainability. The six-rope 6-m Koepe production winder handles a 55- metric ton (mt) payload using a twin drive of 11 megawatts (15,000 total horse power). When operational, it will be the flagship Koepe winder within the SIEMAG TECBERG Group and a world leader for hoisting production. Both the Koepe and Blair winders are equipped with custom SIEMAG TECBERG equipment specifically designed for mine winder applications. The Koepe winder is equipped with the BG 100, the company's largest slide bearing size (1,000-mm seat), and the Blair hoist features the BG 90 (875-mm seat). Both winders have 12 BE200 brake element pairs and four-channel closed-loop elec- trohydraulic brake control systems (providing constant retardation brake) with SIL3-level components. SIEMAG TECBERG supplied a six-rope 6-m deflection sheave set for the Koepe production winder. A new generation 4-m compensa- tion sheave was developed (patent application in process) for the Blair service hoisting system. The sheave compensation system con- sists of two independent and vertically guided sheaves connected to two hydraulic cylinders. This arrangement maintains similar force in the two Blair ropes to prevent unsymmetrical loads (with direct improvement for safety and rope life). The sheave compensation unit includes a specially designed hydraulic station with electrical con- trol system, which drives and controls the operation of the sheaves. Manufacturing of the equipment was largely completed during 2012. Workshop assembly and factory acceptance tests were com- pleted in the first quarter of 2013. Following this, the equipment was packed and shipped to Canada and stored until May 2016 awaiting installation. Installation began in May 2016 and erection is scheduled to be finished in early 2017. Cold commissioning (without loads) will follow this, and hot commissioning (with loads) is scheduled for later in 2017. This multiyear project required diligent and flexible management in all phases of the project. The SIEMAG TECBERG six-rope 6-m Koepe production winder for Mosaic K3 during installation in November. The headframe for Mosaic's K3 shaft rises above the Saskatchewan prairie. Underground Mining Where Power Meets Safety

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