VDMA

INDA 2017

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 29 2017 • VDMA MINING SUPPLEMENT "More and more mines today prefer the packaged crushing plant based on the raw feed capacity and feed required by the pro- cessing plant," Drescher said. "That approach puts us in more of an OEM system supplier position." Maintaining a certain level of technology, thyssenkrupp has managed to optimize pricing to a point where they can compete in the standard machine business. "We are working directly with local markets and dealers and that's a fundamentally different view from the 'tailor-made' mining business. It's a different approach to engi- neering as well as keeping equipment in stock," Drescher said. Jabs explained that the tailor-made solutions for mining are part of the company's DNA. "That's how we roll," Jabs said. "But now thyssenkrupp is trying to transfer that DNA also to the mass mining market. Some of these smaller cone crushers and other items are sold as a commodity." The custom-made mindset has prevented the com- pany from competing for the business in these markets in the past. "We have dedicated teams serving this market now," Drescher said. "Local business units have adopted this very quickly and it's a driving element to be closer to the customer and to provide those services quickly." Bridging Gaps With Grinding Technology Using the expertise within the business area, thyssenkrupp can en- gineer systems to mine and transport phosphate and fertilizers from pit to port. "Working with our colleagues in Dortmund, who design fertilizer plants, thyssenkrupp can design the entire beneficiation process as well as the ship-loading process," said Uwe Schuh, head of department grinding technology mineral processing, thyssenk- rupp. "We are currently looking at several projects in North Africa." Phosphate can be exported as ore (phosrock) or a liquid (phos- phoric acid). India imports a lot of phosrock; other destinations, such as Brazil, would rather receive phosphoric acid. thyssenkrupp has been looking at fine grinding as a way to re- duce water and energy consumption (See Minerals Processing, p. 32). Using the experience gained with phosphate grinding in dry regions, the company believes it can parlay that into savings for other metal recovery plants. They recently received an order from Ma'aden in Saudi Arabia to install crushing and dry grinding equipment within a fertil- izer plant in a very dry region. "This will be the first HPGR application for phosphate ore," Schuh said. "They have limited water resources and this installation will come online during the first quarter of 2017." Developments with grinding have helped bridge the gap with thyssenkrupp as it relates to its service initiatives. "Our service cen- ter in Chile was developed to support HPGR refurbishments," Jabs said. "Today, however, it is acting as an equipment rebuild facility. We recently had a shovel undercarriage in for a rebuild. There is no limit to the services that we can provide." The company could also say that about their service centers, located near Perth and Johannesburg. Reducing or Eliminating Trucks The Mining Technologies business unit within thyssenkrupp contin- ues to develop solutions to eliminate or reduce the use of trucks. "When we discuss new projects with mining clients, the first thing they want to evaluate is whether it is possible to mine and transport ore without trucks — that is a significant change in thinking from just a few years ago," Jabs said. "Even customers in the oil sands have started to investigate new mine developments without trucks. Whether they can accomplish it or not is yet to be seen, but at least they are thinking about it at an early stage. That increases the re- quirements for fully and semimobile crushing stations." The backbone for all these techniques is the conveyor system. "We have brought forward many developments with gearless drive systems and we continue to build our position," Jabs said. "During 2016, thyssenkrupp acquired the Overland Conveyor Co. in Denver and this brings even more conveyor expertise onboard." The company is still refining solutions for steep-angle convey- ing. "Right now, we see the greatest potential with the Megapipe for steep angle conveying," Jabs said. "Working together with Contitech and Siemens, thyssenkrupp has made a significant investment in terms of tests and prototyping. We conducted a lot of tests and we're sure that this is something that is going to fly quickly." Beyond that, thyssenkrupp is always on the lookout for other solu- tions, Jabs explained. "There is conventional conveying and then we have some big ideas, but we need something to bridge the gap," Jabs said. "The imagine gap between what miners are accustomed to seeing and the possibilities that are out there. It's two extremes. The Megapipe is definitely in between what currently exists and the extreme steep angle conveying solutions." IPCC was a revolutionary change 10 years ago, Jabs explained, and now steep-angle conveying will be the next game changer. Conveyor Ensures Dust-free Transportation of Ore Concentrates Transportadora Callao S.A., the logistics operator of a special cargo terminal at the Port of Callao in Peru, relies on a pipe conveyor to transport zinc, copper and lead concentrates from the warehouse to the terminal. With its ability to navigate curves in three dimensions, the conveyor could be optimally adapted to its 3,000-m routing course. More importantly, the conveying system prevents the con- centrates from escaping into the environment, ensuring dust-free transport to the ship's holds. The Beumer Group handled the engi- neering, procurement (including the steel structure), construction management and commissioning of the system. Located on the Pacific Ocean, Callao is a large Peruvian city, with the largest airport in the country and one of the most import- ant fishing and commercial ports in South America. A modern ship loading terminal for ore concentrates was built in this port and it is operated by Transportadora Callao S.A. With its ability to navigate curves in three dimensions, Beumer recently installed a 3-km pipe conveyor to transport concentrate to a new terminal at the Port of Callao in Peru.

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