JAN-FEB 2018

Best of Germany 2014 - Mining Equipment and Mining Technology

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VDMA 14 VDMA MINING SUPPLEMENT • 2018 height from the PM32 and the position of the AFC, it calculates the necessary cut sequence and transfers it to the shearer control sys- tem. The graphic visualization of the face is not only shown in the control room on the surface and the headgate computer, but also on every PM shield control unit. Becker pointed out that, due to cus- tomer requirements, no connection to the surface is required, as the entire process is done on the underground IFC-computer. In the future, corrections will be made automatically based on the roof and the boundary layer. "In Russia, we have a face that is perform- ing a boundary analysis with the sensors on the shields, so we can rec- ognize any boundary violations," Becker said. "That data is fed into the IFC, where adjustments are calculated and transferred to the shearer." Looking toward the future, Becker discussed an inertial navigation system. "Independent of the longwall manufacturer, we want to be able to exchange cut data with the shearer," Becker said. "We have an in- ertial sensor attached to the frame of the shearer. It is connected to a PM32 and just like every PM shield, it has an RFID antenna. To determine machine geometry, we will place additional inclination sensors on the ranging arms. With our cameras in every fifth or 10 th shield, the system will identify the marker band and make a cut correction automatically." For an autonomous longwall to plan cuts intelligently, the in- tegration of the shearer is essential. The industry already has the prerequisites. With further developments, such as the inertial navi- gation system, autonomous longwall mining will soon be within the industry's grasp. Engineering Russia's Deepest Shaft-hoisting System Norilsk Nickel plans to pursue ore at deeper levels, and the company recently approached SIEMAG TECBERG to provide what is believed to be Russia's deepest shaft-hoisting system. Over the years, the com- pany has provided hoisting equipment for many Norilsk Nickel instal- lations, but this one, the SKS1 project, is different. In addition to being more than 2-km deep, SIEMAG TECBERG will be supplying a complete shaft-hoisting system with a defined yearly ore output for the Siberian nickel miners, rather than simply supplying individual components. The SKS1 project will add around 500 m depth to other exist- ing hoisting installations in Russia. It will use two types of hoist- ing arrangements, a Koepe system for service applications and a double-drum Blair system for the production. "For this project, we are supplying a complete system with the best hoisting technology, designed based on long years of experience," said Michael Krenzer, senior project manager, hoisting technology, SIEMAG TECBERG. "This will also be the first Koepe system used at a hoisting height of 2-km." Both systems were designed, engineered and manufactured by SIEMAG TECBERG. Both will be equipped with SB1 decel- eration-controlled brakes and the company's own types of slide bearings and brake elements. The four-rope Koepe hoist of Ø 6.5m will be used for service. In ad- dition to the hoist, the system will have two sets of Ø 6.5-m deflection sheaves, a large cage and counterweight with rope attachments, head and tail ropes, supplied together with a four-point lifting system to install the heavy-load components. It has a 20-ton payload and maximum operating load of 360 tons (T1 + T2). The double-drum Blair production hoist of Ø 5.75 m has two ropes per drum, rope-load compensating sheaves, the related steel work with guiding beams and two 30-ton skips. SIEMAG TECBERG de- signed a complete loading system at the shaft bottom as well as the discharge system on the surface, supplied together with the required belt conveyors. SIEMAG TECBERG also designed the head-rope attach- ments and selected head ropes for carrying the skips and payload. "We are now in the supply phase," Krenzer said. "This hoisting shaft is currently scheduled to go into operation during the fourth quarter of 2019." They are also providing rope-handling equipment, such as a 200-ton, four-rope clamping and lifting device (2,000- kN), a 1,800-kN friction winch with a component weight greater than 150 tons, along with rope reelers, messenger winches, related horizontal and vertical deflection sheaves, and special tools. In addition to its hoisting system construction experience, SIEMAG TECBERG is also familiar with the local Russian machine building guidelines. "An important part of the equipment supply was to be certified to fulfill the local requirements for explosion pro- tection to work underground," Krenzer said. The double-drum Blair production hoist is powered by an 8.6-megwatt motor. The weight of the drum shaft alone is 90 tons. The 30-ton skips will travel at 14 m/s to hoist approximately 1.5 million tons of ore per year to the surface, based on 12 operating hours per day and 330 days per year. "The double-drum Blair hoist uses rope-load compensating sheave technology, and this is only the second time we have supplied this complex technology," Krenzer said. "The hoist has two ropes at- tached to each drum. For different reasons (e.g., rope elongation), the rope load varies. Basically, each sheave is supported by a hy- draulic cylinder that is hydraulically connected with the cylinder of the corresponding second sheave, which enables load compensation for each other. The use of this system avoids long-term damage of the hoisting ropes. If for whatever reason a rope coiling failure oc- curs, for example, this system would detect it immediately and the hoist can be brought to a safe stop." The double-drum Blair production hoist of Ø 5.75 m has two ropes per drum, rope-load compensating sheaves, the related steel work with guiding beams and two 30-ton skips. The Blair hoist uses load compensating sheaves to avoid long-term damage.

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