INDA 2017

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 25 2017 • VDMA MINING SUPPLEMENT based on the high-pressure plunger pumps, which have been used by the mining industry for decades. "The reduced noise level requirement was difficult to meet with the existing drive concept of the KAMAT pumps because the crank- shaft, which moves the plunger via crossheads, had to be asymmet- rical to accommodate it in the previously undivided housing," said Dr. Andreas Wahl, CEO, KAMAT. "The asymmetry resulted in stronger vibrations, which made it difficult to achieve acoustic decoupling by means of damping elements." The new drivetrain features a split housing in which a symmet- rical, balanced crankshaft takes over the power transmission be- tween the drive and the plunger. "The newly designed double-helical gearing also helps to improve the smoothness in operation and to reduce the noise emission from the pumps," Wahl said. The new design is now incorporated in the triplex pumps of the performance classes from 80 kW to 400 kW. It also forms the basis for the design of the quintuplex pump drives in the performance classes from 530 kW to 800 kW, which KAMAT has developed for series produc- tion and has the potential to bring about significant cost savings from an operator's point of view when large volume flows are requested. The mechanical part of the drive creates the prerequisite for a demand-oriented, variable speed control of the pumps, which is one of KAMAT's core competencies. The power transmission design de- tails include large surfaces for a low surface pressure and the amply dimensioned crosshead. "They ensure an excellent, hydrodynamic lubrication of the pump drive at the spots with the highest loads even at a low rotational speed," Wahl said. "Since KAMAT plunger pumps are working at full operating pressure over a speed range from 10% to 100%, the plunger pumps are operated in an ener- gy-efficient and demand-oriented way at partial flow." The first KAMAT quintuplex pumps for pressures up to 3,500 bar were another development stage on the basis of the redesigned, en- ergy-efficient triplex plunger pumps, Wahl explained. "This develop- ment was initiated in response to the fact that the (water) hydraulic systems of various high-pressure plunger pump applications — and notably those on longwalls in the mining industry and descaling sys- tems in the steel industry — are getting larger and larger," Wahl said. Today, the operators are using multiple large triplex pumps giv- en that the volume flow of these pumps is limited by design, but also for reasons of the high pressures involved. The cylinder volume is limited by cavitation, which implies that it only makes sense to produce triplex pumps with ratings of "only" about 400 kW. The basic design of the new triplex pumps then opened up the option to develop, on their basis, the first quintuplex (five-cylinder) New double-helical gearing reduces the noise emissions from the pumps.

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