INDA 2017

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 24 VDMA MINING SUPPLEMENT • 2017 agenda and it looks we're again defining the performance and TCO benchmarks." Eickhoff also had the brand new 36-type continuous miner (3.6- m cutting height) shipped recently to South Africa. The machine weighs 83 metric tons (mt) and has 2 x 180 kW cutting power. "There is great potential for these machines," Lange said. "We took an ex- isting 37 model, which is shorter and lighter, and modified the main- frame making it longer and heavier for the South African market. The coal in this region has a high compressive strength. So, we modified the kinematics of the mainframe as far as the hinge point of the cut- ter boom, which allows the operator to apply more power at the face." Eickhoff's South African continuous miner fleet will significantly grow in 2017 — besides that local success, they see a promising global market for hard coal equipment sales. Advancements in Underground Haulage When it comes to haulage, mines have three options: rail, rub- ber-tired machinery and conveyor system. While the mining industry drifted away from rail haulage, Matthias Pütz, sales manager for Schalke Eisenhütte, emphasized it is still a competitive option for transporting ore. Schalke manufacturers locomotives that are cus- tom-designed for underground haulage systems. Schalke is currently negotiating with China on a major project. The company shipped the first locomotives to Freeport-McMoRan's Grasberg mine in Indonesia in June. Even though the project was delayed, they installed a test track on the surface to get operational approvals. "A total of 10 locomotives were ordered for Grasberg," Pütz said. "The last two will be produced in the fourth quarter of 2017. When the locomotives begin operating underground, they will start with diesel-powered systems until the catenary system is con- structed, then they will switch over to electricity." More recently, Schalke has been working with project developers to reinforce rail haulage as an option at the prefeasibility stage. "We have been involved with several scoping studies, including the expansion at Olympic Dam," Pütz said. "They recently decided to go with rail and they have started the second stage of the study." Pütz has also worked on scoping and bankable studies for smaller mining companies. "The Seabridge KSM gold mining project in British Columbia was planning a conveyor system through the mountain to the mineral processing plant, but we have now con- vinced them to use rail haulage, especially as it relates to reduced operating expenses," Pütz said. Schalke received its first order in North America last year and it sees a lot of potential in that market. "In May, we received an order from Manitoba to replace three old Goodman locomotives with a semi-automated system," Pütz said. Currently, Schake is developing a new locomotive in the 10- to 20-ton range, which could be used for service as well as production. It would be based on Schalke's Modutrac system and has the same parts as a standard locomotive, such as the frame and the driver's cabin. This avoids the long delivery times associated with a cus- tom-made locomotive. For the last two years, Schalke has been working with the Insti- tute for Mineral Resources Engineering at the University of Aachen to develop an inexpensive Excel-based tool to compare the capital and operating costs associated with the three main haulage sys- tems. Pütz said it was nearly finished and are awaiting the results. Energy-efficient Pump Stations for Powered Roof Supports Modern roof supports require higher pressures, bigger cylinder diameters, and faster advance rates than their predecessors. All these requirements depend on the high-pressure pumps. At the same time, longwall operators are looking for ways to significant- ly reduce noise levels and improve energy efficiency. In response, KAMAT has developed a new series of speed-controlled plunger pumps for pressures up to 3,500 bar and motor ratings up to 800 kW. The company combined an upgraded mechanical drivetrain with a variable speed controller, which allows one system to replace mul- tiple small pumps with one bigger and well-controllable high-pres- sure pump or with a master-slave combination. The forces introduced into powered roof supports are increasing considerably along with longwall face lengths and the depth of min- ing. As a result, the hydraulic pressures and cylinder diameters of the shields are increasing as well. The higher cutting speeds of the shearer loaders additionally require a faster advance of the shield supports. All these factors are setting high requirements for the ef- ficiency of the hydraulic stations in use. Adding to this are new, more stringent requirements for the en- ergy efficiency and noise levels. The pump stations are located more and more often in the immediate vicinity of the longwall controls in the headgate. While total cost of ownership and energy costs are a concern, longwall operators are also looking for more compact design because of the confined space. KAMAT understands these conditions and has successively developed a new pump series that features a new drivetrain. It is Eickhoff tests a fully automated low-profile 300 SL shearer loader at its factory in Bochum, Germany. Looking at the low-profile shearer loader from the deck of the armored face conveyor, one can see that Eickhoff has engineered it in such a way that it still has the clearance for high-capacity production.

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