Indonesia - Coal Age

OCTOBER 2016

A MINING MEDIA PUBLICATION Indonesia

WWW.MINING-MEDIA.COM

RTC Kalimantan Mining Power Project

PLN’s 2016-2025 10-year

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October 2016 | Coal Age Indonesia • 1

Features

From the Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Report From RTC Kalimantan Mining 2016: Power project to help miners mitigate Coal downturn . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PLN’s long-awaited 2016-2025 10-year electricity supply business plan (RUPTL) finally issued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Report from Sumatra Miner 2016: Sumatra Mining fast tracked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Fitch Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Geo Energy secures life of mine coal offtake deal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Rinjani and CK agree to lower waste mining rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

BPI secures financial close for 2 x 1.000 MW power plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Blackgold announces new estimate of coal resources and reserves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

GEAR plans to double coal output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

On the Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

BBM project comprises 90% of coking coal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

OCTOBER 2016

A MINING MEDIA PUBLICATION Indonesia

WWW.MINING-MEDIA.COM

http://WWW.MINING-MEDIA.COM

2 • Coal Age Indonesia | October 2016

Declining exports and foreign investment plus pressure

from anti-mining lobbyists have spurred the government

of the Republic of Indonesia to reconsider, retract or

rescind, redraft and possibly implement new regulations

and policies. This week’s World Bank revelation that

Indonesia’s GDP growth is unlikely to go beyond 6% by

2018 has everyone rethinking!

Dwindling geothermal exploration (and in fact any

other mineral exploration) and overlapping local, state

and federal regulations can and have impeded any sig-

nificant growth in the exploration of resources to meet Indonesia’s economic

growth and electricity demand. Progress in renewable energy resources is

far too slow to meet such demand.

The Indonesian government wants to add 35,000MW to the nation’s energy

capacity by 2019 and there is no question that coal is a definite requirement to

achieve such a goal. Some companies have been given government approval

to produce more coal and GEAR (Golden Energy) is one such recipient of

this approval, while thermal coal producer Geo Resources has found more

reserves; Cokal reserves at BBM are confirmed to be highly metallurgical

coal; and Blackgold has announced its coal reserves in Riau.

Coal miners wanting to diversify their business so as to offset coal price

reductions have set their sights on becoming power generators and power

plant developers. Adaro is the biggest example here followed by Tambang

Batubara. Adaro is, in fact, the driver for the $4bn Batang power plant proj-

ect in Central Java. Construction of this power plant is soon to commence

following the successful financing received by the BPI consortium, which

includes Adaro.

Recent share price increases in listed coal mining companies on the

Jakarta Exchange is a welcome sign but some analysts remain cautious,

particularly as China’s economic slowdown continues and whilst the global

economy remains volatile. Nevertheless, China’s slowdown and the closure

of some 1000 coal mines so as to adhere to the statutory working days in coal

mines, actually means a boost for coal imports. China may well be looking for

more coal from both Indonesia and Australia in the coming year.

Another boost for the Indonesian coal business is being driven by Coal

India’s (CIL) asset shopping in Indonesia. CIL is eyeing several deposits and

will over time acquire such assets via a government to government arrange-

ment. Acquisition of such assets will reduce CIL’s reliance on coal imports.

Reduced exploration and reduced production means a softening in the

purchase of mining equipment and services in this region. A recent report

on the global mining machinery market indicated the potential for growth in

mining equipment sales in the Asia Pacific region but this is predicated on

equipment purchases in the metals mining industry, more specifically in the

iron ore and bauxite camps and not so in the coal industry. Stationary surface

mining equipment litters the coal sites while most servicing of such equipment

is done in-house.

Improved clean coal technologies and innovations may see some growth

in Indonesia.

Recent conferences conducted by Mining Media on coal and mining in

Indonesia have provided insight, opportunities and prospective resolutions

to issues in infrastructure to mine, as well as technologies that can assist in

optimising mine production.

Meantime, coal mining continues in Indonesia and the industry is optimistic.

From the Editor

www.mining-media.com

E&MJ/Coal Age Indonesia®

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Camberwell, Victoria, 3124,

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Phone: +61 3 90061742

Editorial director - Steve Fiscor, [email protected]

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Latin America - Oscar Martinez, [email protected]

South Africa - Gavin du Venage, [email protected]

SALESPublisher - Lanita Idrus, [email protected]

North America - Victor Matteucci,

[email protected]

Germany, Austria, Switzerland - Gerd Strasmann,

[email protected]

Rest of Europe - Colm Barry, [email protected]

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Japan - Masao Ishiguro, [email protected]

Indonesia -Dimas Abdillah, [email protected]

Mining Media International

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E&MJ/Coal Age Indonesia® is published once per year by

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ensure that the contents are correct at time of publication.

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ISSN: 1832-7966.

Indonesia

Lanita Ldrus

State of Power

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Indonesia


NEED PHOTO

Indonesia


IntroductionThe Kubria® cone crusher from Thyssen-

krupp (see Fig. 1) has proved effective

for many years under the toughest appli-

cation conditions in the field for hard-rock

crushing. It is used mainly in the aggre-

gates industry for the secondary and ter-

tiary crushing of granite, basalt, gneiss

and other hard rock, as well as in the

mining and cement industries.

The Kubria® product line was recent-

ly updated to include the latest techni-

cal developments, and standardised to

assure uniform manufacturing standards

maintained at Thyssenkrupp locations around

the world. The result is that the crusher can

now be offered very competitively and with

significantly lower delivery times.

Fig. 1: Kubria® cone crusher

Design and functionThe Kubria® crusher design has a hy-

draulically supported main shaft and

fixed upper crusher chamber. Crushing

takes place between the concaves in the

crushing chamber and the mantle lined

crushing cone (see Fig. 2), which is ro-

tated by an eccentric drive in the lower

section.

This design allows the gap between

the concaves and the crushing cone to

be continuously decreased or increased

all around the periphery. As the crushing

chamber narrows, crushing of the mate-

rial is achieved by means of increasing

pressure on the rock. The geometry of

the crushing chamber and the eccentric

stroke can be individually adapted to

specific crushing requirements as de-

termined by the material characteristics.

This is particularly important when the

raw material properties or the product re-

quirements change during the service life

of the crusher.

Fig. 2: Main components of the Kubria®

cone crusher

The maximum possible feed size for the

crusher is determined by the opening

width at the top of the crushing chamber.

The finished product lump size is deter-

mined by the closed-side setting (CSS)

in the discharge zone.

The wear material components in

the crusher are made of wear-resistant

austenitic manganese steel that can be

replaced easily. The crushing cone con-

sists of a mantle fit on the cone body that

is in turn firmly connected to the main

shaft. The crushing ring is fastened in

the top shell of the crusher. “G” mod-

els for coarse crushing are additionally

equipped with annular arranged con-

caves. The top shell and bottom shell are

both made of cast steel. The ‘spider’ in

the upper area of the top shell is used

to support the upper shaft bearing. This

spider is also made of cast steel and has

spider arm liners. As all wear parts and

heavy internal removable components

parts are accessible from above, the

crusher is very easy to maintain.

A thrust bearing is used to support the

main shaft on a hydraulic cylinder. This

cylinder is used to control the crusher

setting by raising and lowering the shaft.

If tramp material is experienced in the

crushing chamber, the shaft is lowered

automatically, allowing the tramp mate-

rial to largely pass through the crushing

chamber without resulting in damage to

the crusher. For run of mine materials

that are very hard and tough to crush, the

main shaft is equipped with a hydrostatic

thrust bearing assembly for operating at

high crushing pressures.

The drive and the hydraulic cylinder

are housed in the bottom shell of the

crusher. The Kubria® bevel gear teeth are

cut with a cyclo-palloid process that was

specially developed for this crusher. It

provides for smooth, low-wear operation,

which also allows higher drive powers to

be transmitted. The result is that Kubria®

cone crushers can be equipped with big-

ger motors. In addition, these crushers

are characterised by a long service life

and easy accessibility for maintenance

work.

The crusher is equipped with a circu-

lating lubrication system to supply oil to

the eccentric bush bearing assembly,

the axial bearing assembly and the bev-

el gears, and is also equipped with an

automatic grease lubrication unit for the

spider bearing.

Today’s quarry operations increasing-

ly require automation of plant systems .

This also applies to the crushing circuit.

The Kubria® crusher is typically deliv-

ered with the proven Kubriamatic control

system, which can be integrated into the

control system and the dynamic process

display of the overall plant.

With the Kubriamatic control system,

the crusher settings can be changed

during operation. It is also used to enter

and monitor the crusher-specific operating

data such as closed-side setting, operating

power and pressures, as well as tempera-

tures and the oil flow conditions. Further,

important operating data such as operat-

ing hours and load and no-load hours, as

well as the number of pressure and power

peaks, can be called up. The crushing set-

ting is regulated automatically according to

adjustable power and pressure limits. Au-

tomatic setting adjustment is carried out

to keep the product quality of the crusher

The new Kubria® cone crusher from thyssenkrupp

Authored by: Peter Berlitz

Dr. Armin Greune

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constant as the crusher concaves and

mantle liners wear.

Design and applicationFor the aggregates industry, Kubria®

crusher sizes 90, 110 and 130 are com-

monly used. The number denotes the

lower cone diameter. “G” models for

coarse crushing and “F/M” models for fine

and medium crushing applications are

available for each size (see Fig. 3). The

coarse “G” model crushers are equipped

with a steeper cone, while crushers for

fine and medium (F/M) crushing have

a more flat cone. The steep cone angle

results in achieving higher throughput

rates. The use of the flatter cone angles

in the F/M crushers means a particular-

ly high-quality product can be achieved.

The design of the bottom shells for either

the “G” or “F/M” models is identical.

The coarse crushers are used mainly

in the second crushing stage. They can pro-

cess feed sizes of up to 450 mm. The fine

and medium crushers are used for second-

ary and tertiary crushing. Here, feed sizes of

up to 230 mm can be handled.

All versions of the Kubria® cone crush-

ers are characterised by the fact that the

material has a relatively long retention

time in the crushing chamber, with a cor-

respondingly high number of crushing

steps. As a result, a product of high cu-

bicity is produced, which is important for

meeting product standards required for

concrete aggregate and other products.

The Kubria® product name is based on

the high cubicity product it produces.

Fig.: 3

Kubria® G type Kubria® F/M type

Application exampleOne example of the use of Kubria® cone

crushers is in a three-stage crushing plant

for the production of crushed stone. The

flowsheet for this plant, which has a total

capacity of 250 tph, can be seen in Fig. 4.

Depending on the requirements of the

producer, the plant can be designed as a

stationary plant, a semi-mobile crushing

plant, or a wheel-mounted portable plant

in which the crushers and the associated

screens are combined into modules.

The 0–600 mm size run of mine mate-

rial is discharged from a bin by means of

a grizzly feeder where the initial primary

screening takes place. Furthermore, a

fine-screening stage is used to remove

natural contaminants such as soil and dust,

which are not wanted in the end product.

In the first crushing stage, the material

is crushed to 200 mm by an EB 11-08 jaw

crusher. From there, it is conveyed to a

secondary “G 90” cone crusher where it

is crushed to a size of 50 mm in closed

circuit with a screen. The product from

the secondary crusher will already meet

product standards, so the 25–50 mm

fraction can be screened out and sent to

product stockpiles for use as railway bal-

last, drainage systems or other products.

In the tertiary crushing stage, a

Kubria® F/M 90 is used in a closed cir-

cuit to produce the required end product.

The product is then split into the various

product size ranges by a circular vibrat-

ing screen with 4 decks. By adjusting the

close-side settings of the secondary and

the tertiary crushers, it is possible to pro-

duce a final product containing a particu-

larly high portion of the desired fraction.

Fig. 5 shows some typical product curves

for a fine and medium crusher, with dif-

ferent crusher settings.

Fig. 4: Flowsheet for a three-stage crush-

ing plant for the crushing of granite

Thanks to the optimised crushing cham-

ber geometry, the product of the tertia-

ry crusher contains a high portion of the

required fraction, which means that only

approximately 5% of the feed volume

has to be recirculated. This results in low-

er wear of the crusher manganese and

therefore higher availability for the crush-

er and reduced operating expenses.

Overall, the use of Kubria® cone crush-

ers allows the implementation of a plant

concept that is characterised by efficien-

cy, flexibility and a product that meets the

highest quality requirements. With the

use of modern control systems, a high

degree of automation and user-friendli-

ness can additionally be achieved.

Fig. 5: Typical product gradation curves of

Kubria® cone crushers based on crusher setting

A plant based on flowsheet shown in Fig.

4 was delivered to Cameroon earlier this

year as a wheel-mounted portable plant

system. All components were designed

and manufactured by thyssenkrupp. The

mobile modules, feed bins, surge bins

and belt conveyors used were taken

from the standard range of processing

machines. Assembly and commissioning

were also carried out by thyssenkrupp,

which provided a turnkey plant that was

handed over to the customer.

SummaryThe new Kubria® series of cone crushers

from thyssenkrupp offers extremely com-

petitive machines for coarse, medium

and fine crushing to the aggregate indus-

try. In operation for decades, these ma-

chines have proved effective under the

toughest conditions for crushing granite,

basalt, gneiss and other hard rocks, as

well as in the ore processing industry.

Incorporating the latest technology, these

machines provide:

• High-cubicity finished product

• Low wear and low operating expenses

• Rapid crushing setting adjustment

• Variable crushing chamber configurations for

adaptation to product requirements

• Ease of maintenance, with low maintenance

downtimes

• High level of operating reliability and process

control with the Kubriamatic control system

• Solutions for mobile, semi-mobile or station-

ary plant requirements.

For detailed information, please send us your

inquiry to:

P.T. Thyssenkrupp Industrial Solutions

Indonesia

Tempo Scan Tower, 20th Floor

JI. HR. Rasuna Said Kav. 3-4

Jakarta 12950

Tel: +62-21-2939 2800

Fax: +62-21-2939 2804

Email: [email protected]

Website: www.thyssenkrupp-industrial-solutions.com

Sponsored Content


http://www.thyssenkrupp-industrial-solutions.com


Indonesia


Indonesia

Makes Geo Energy one of the top

10 coal producers in Indonesia


Indonesia

VDMA

A supplement to E&MJ, Coal Age, Equipo Minero, E&MJ/Coal AgeChina, E&MJ/Coal Age Russia, E&MJ/Coal Age India, E&MJ/CoalAge Africa, E&MJ/Coal Age Indonesia and The ASIA Miner

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Smooth operation at bigger flows

Product data Parameters

1185 l/min (max) at 350 bar Fluid Viscosity

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2016 • VDMA MINING SUPPLEMENT VDMA 15

Published by

Mining Media Int’l

in cooperation with

the VDMA MiningEQUIPO | INGENIERÍA | TECNOLOGÍA

Articles in this publication were researched, edited and written by Steve Fiscor, editor-in-chief of Engineering & Mining Journal (E&MJ) and Coal Age. For addi-

tional information about the articles or the manufacturers highlighted here, please contact Mining Media International ([email protected]).

Commodities that cannot be harvested must be produced in an alternative matter: recycling or mining.

Recycling fails due to some deficiencies. Mining is the most effective method to extract raw materials.

This applies not only to fossil raw materials, but also to all metal and mineral raw materials essential for

alternative power generation, including raw material requirements for the storage of alternative generated

power, e.g., battery storage. Energy revolution without mined commodities will fail to function.

Also an essential point to judge the importance of mining and mining equipment is the demand of people in

developing countries for a reliable supply of heat and energy as well as improvements in infrastructure. Both

need raw materials and, consequently, mining to overcome these disadvantages. The highly developed, safe

and proofed mining technology is provided by German mining equipment manufacturers.

If mining is indispensable for the foreseeable future, the aim is to act as safe and environmentally friendly as

possible. German manufacturers of mining equipment have taken great efforts to optimize operational safety of

the machines. In cooperation with their worldwide customers, this leads to a unique level of safety, particularly

for underground mining. This also leads to substantial improvements in energy consumption, optimized endur-

ance of machines and plants, and higher efficiency in total. Further advances in technology will be achieved

by Industry 4.0 or Mining 4.0. Different approaches are followed by the industry and all experts agree that the

future of mining will be digital.

This edition of Best of Germany focuses on work being done by VDMA Mining member companies to give

the best possible support to the global mining industry. We hope that you find value in this publication, wherever

you are in the world.

Glückauf!

Dr. Michael Schulte Strathaus

President

VDMA Mining

Foreword:

Table oF ConTenTs

A Special Supplement to

E&MJ/Coal Age Indonesia

Produced by Mining Media International

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www.vdma.org

Your Contacts in the Mining Equipment Association . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

VDMA Mining Realigns to Meet the Industry’s Needs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Underground Mining: Where Power Meets Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Surface Mining: Moving More Rock Safely and Cost Effectively . . . . . . . . . . . . . . . . . . . . 25

Mineral Processing: Improving Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Material Handling: Engineering Modern Conveyor Systems . . . . . . . . . . . . . . . . . . . . . . . 33

Innovations: An Assortment of Equipment for Mines and Mills . . . . . . . . . . . . . . . . . . . . . 37


http://www.mining-media.com

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16 VDMA 2016 • VDMA MINING SUPPLEMENT

Your Contacts in theMining Equipment Association

Joachim Schmid Managing Director

Phone: + 49 69 6603-1261

Fax: + 49 69 6603-2261


Helmut Schgeiner Director

Technology, standardization and research,

markets Europe, Africa, USA and Canada

Phone: + 49 69 6603-1680

Fax: + 49 69 6603-2680


Christoph Danner Manager Markets

Latin America

Phone: + 49 69 6603-1254

Fax: + 49 69 6603-2254


Alexandra Landgraf Assistance

Phone: + 49 69 6603-1577

Fax: + 49 69 6603-2577


Rajesh Nath Chief Representative

VDMA Representative Office India

Phone: + 91 33 2321-9522/7391

Fax: + 91 33 2321-7073


Sven Flasshoff Chief Representative

VDMA Representative Office Russia

Phone: + 7 499 41803-71

Fax: + 7 499 41803-72


Klaus Stöckmann Deputy Managing Director

Economy and statistics, trade fairs,

markets Asia and Australia

Phone: + 49 69 6603-1270

Fax: + 49 69 6603-2270


Monika Bind Manager Markets

CIS and Russia

Phone: + 49 69 6603-1262

Fax: + 49 69 6603-2262


Jörn LehmannManager Standardization

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Phone: + 49 69 6603-1577

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VDMA Representative Office Brazil

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VDMA Representative Office China - Beijing

Phone: (+86 10) 87 73 02 12-8 08

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VdMa Mining: MeeTing indusTry

needs during unCerTain TiMes

The Mining Association within the German Engineering Federation

(VDMA), now known as VDMA Mining, consists of a little less than 120

companies that provide equipment and services for underground min-

ing, open-cast mining/materials handling and mineral processing tech-

nology, along with consulting, and research and development services.

Many of these companies are privately held. In total, these companies

represent approximately 90% of the German turnover related to mining

and mineral processing equipment and services.

The Best of Germany 2016 offers insight into all of the areas

served and reports on new developments. It quickly becomes apparent

in each section how much VDMA Mining contributes to the advance-

ment of mining and mineral processing. In addition to equipment and

technology, VDMA Mining is also contributing to the modern dialogue

in areas of safety, engineering, training and environmental sustainabili-

ty. This supplement concludes with a listing of member companies and

a matrix describing the services each company provides.

VDMA Mining members pool their competencies to foster busi-

ness-to-business relationships in the mining sector. The association

also represents member interests toward politics in Germany, Europe

and other countries where they do business. As an example, the group

is already looking to restore mining and milling operations in Iran. They

exchange their experiences in several committees and set common

objectives. As part of the greater VDMA umbrella, they have access to

legal services, foreign trade experts, global economics and statistics,

industry standards, and insurance services.

ALong-term VisionCurrently, the mining business finds itself in uncertain times. Prices for

many metals are well below the record levels the industry experienced

only a few years ago. In the short-term, it appears that gold and iron ore

will experience a modest recovery, but prices for base metals remain

soft. Coal consumption, which consistently grew at 2% to 4% annually

for decades, posted a significant downturn last year. Factories are con-

suming less power and steel mills have slowed production, so the two

largest coal producers, China and the USA, have simply seen demand

erode and, in some cases, replaced with natural gas.

This swing in market fundamentals has left its mark on German

mining machinery manufacturers’ balance sheets as well. The industry

expects a 3% drop in sales to 3.62 billion Euros (nearly $4 billion) for

2015. Still, they have a positive outlook for the future.

Germany knows the situation first hand. The downward trend has con-

tinued for its domestic market for mining machinery. Political discussions

about the future of lignite-fueled power stations “is putting pressure on in-

vestment levels,” said Dr. Michael Schulte Strathaus, chairman of VDMA

Mining, at its annual press conference, which was held during November

at the Zollverein mine in Essen. He announced a decline in sales of some

8% to 210 million Euro ($229 million) for the industry in the current year. A

continuing decline in profits is expected for 2016.

The German manufacturers expect a 3% fall in international sales

to 3.41 billion Euros ($3.71) in 2015. The Mediterranean and Middle

East account for the largest export markets (17%). Saudi Arabia has

become the largest customer with an 8% share. Together with Iran,

governments there want to reduce their dependency on oil, according

to Schulte Strathaus. Mining is being developed as an additional main-

stay. Latin America is the second biggest sales region with an 11%

market share, followed by China with 8%, the USA with 7% and Russia

with approximately 5%.

Decline in ExportsThe industry expects a further low single-figure percentage decline in

exports for 2016. Miners are not investing in many new operations and

they are working to reduce costs at existing operations. In some cases,

they have elected to place the mines on care and maintenance until

metal prices improve. VDMA Mining members understand the cyclic

nature of the business. Already, some analysts see the current cop-

per surplus turning into a shortage by the end of 2017, said Schulte

Strathaus. Given the difficult situation, all in all mining machinery man-

ufacturers have “done really well.” Significant adjustments to staffing


levels have been avoided, with the number of employees falling by only

about 600 to 13,700 over the past 12 months. Short-time work is only

a limited answer to multiple changes in market conditions, said Schulte

Strathaus.

New Areas of Business in SightMining machinery manufacturers hold a positive outlook on the future.

An increasing number of companies are registering a rise in custom-

er inquiries. Some sectors that served coal primarily have diversified

into other areas of business, such as hard-rock mining. They assume

that demand for other raw materials such as those used for the global

expansion in alternative energy and power will increase and those ma-

terials also have to be mined.

VDMA Mining members also see the need for the mining operations

and mills to reduce costs as a further cause for optimism, since this can

only be achieved by increasing efficiency. “And that is where our expe-

rience in machinery engineering and plant design come into play,” said

Schulte Strathaus. A global trend toward increasing safety also benefits

German manufacturers. He also believes that the next construction in-

dustry trade fair (bauma 2016), which be held April 11-16 in Munich,

may well “provide a certain boost.”

Competence Centres HelpSchulte Strathaus particularly welcomed the establishment of four com-

petence centres for mining and raw materials by the Federal Ministry

of Economics. Their goal was to promote the government’s renewable

resources policies on-site in Canada, Chile, South Africa and Australia.

Two further centres are planned in Brazil and Peru. Manufacturers are

cooperating closely with these institutions. “This also allows us to pro-

vide German engineering expertise to new regions,” Schulte Strathaus.

To maintain their leading position, particularly in the underground min-

ing sector, manufacturers have been involved with Industry 4.0, “for much

longer than the term even exists,” as Schulte Strathaus remarked. The in-

dustry presented the first machinery to mine coal or other material entirely

independently and autonomously in early 2010, and in global comparison is

“certainly at the forefront” of modernizing its own production facilities.

Technology Serving the MinesWhat follows in the Best of Germany 2016 are examples of what

VDMA Mining members are doing to improve mining and mineral pro-

cessing operations worldwide. Some of the concepts are forward think-

ing and thought provoking, such as convincing miners to move away

from trucks and toward in-pit crushing and conveying systems. Others

are practical solutions for known problems such as a new mine rescue

vehicle hauling rescue teams to the scene rather than making them

hike the distance.

What sets this group apart from others is their commitment to the

mining business. During soft times, many suppliers in other parts of the

world, especially those that are publicly held, had to table projects and

shed positions to meet quarterly numbers for their stockholders. These

companies, the members of VDMA Mining, are managing through the

cycle and already preparing for the recovery. When it’s time to invest

and expand, the mines will find that they have retained the expertise to

hit the ground running.

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Underground mining has continually evolved from a process that relied

on brute strength and luck to mechanization and better reliability based

on engineering. While underground mining techniques differ consider-

ably by the nature of the formation and strength of the rock, the mines

also have much in common, among others ventilation, getting salable

minerals to the surface effectively, ever increasing travel times and a

high concern for safety. German technology is prevalent throughout the

mining chain and especially underground.

Automated Driverless Rail HaulageSchalke manufactures highly sophisticated mining locomotives. The

company recently sold locomotives to LKAB for the rail haulage system

installed for the new level at the Kiruna iron ore mine in Sweden. The

company has also sold locomotives to Codelco’s El Teniente copper

mine in Chile and Freeport’s Grasberg block cave gold-copper mine in

Indonesia.

During the last two years, Schalke has formed an alliance with Nordic

Minesteel Technologies (NMT) from North Bay Ontario, which supplies

loading and unloading equipment and ore cars for the trains, and Bom-

bardier Transportation’s Rail Control Solution division in Sweden; they

supply the signal systems, automation, train control system for the loco-

motives and track-side equipment.

The collaboration began when the three companies were working on

the Kiruna project under separate contracts. The three companies can

now engineer robust rail haulage systems that feature a high degree

of automation, which translates into high reliability. All of the system’s

components are designed to withstand 25 to 30 years of round-the-clock

operation at maximum capacity.

“This rail haulage consortium has completed three major under-

ground projects,” said Matthias Pütz, sales manager, Schalke. “These

fully automated driverless haulage systems have proven to be extremely

reliable and the interfaces between the three systems work well. We

are now working with Hebei Iron & Steel in China. They are taking their

open-pit iron ore operations underground.”

One of the biggest disadvantages for rail haulage is the significant up-

front capital investment. Schalke has developed a solution to help close

the capital expense gap with the other haulage systems by introducing

the Schalke ModuTrac System. “The biggest advantage of our complete

rail haulage system is the extremely low operating expenses,” Pütz said.

“If you have a long-life mine with high transport distances, rail haulage

offers a distinct advantage, as the cheapest and most reliable, and more

mining companies are converting back to rail haulage.”

Locomotives have evolved along with technology, especially with

drives moving from DC switching to AC inverter technology. Likewise,

a similar leap in technology has taken place with automation, which has

big impact on operating expenses and safety.

“When Freeport starts its operation in the block cave in the end of

2016, the locomotive will employ a modular traction system, which

means it can easily switch from catenary power to battery or diesel

power, reducing upfront capital investment during initial operation,” Pütz

said. “The powerpacks can be replaced in about an hour. This is the new

potential for rail haulage. The only thing that is manually controlled is the

loading of the trains as it requires some experience.”

The production locomotive running at Kiruna weighs 108 metric tons

(mt). This hybrid locomotive is designed with an end cab and is currently one

of the heaviest four-axle locomotive Schalke manufactures. Each wheel-

set is driven by a 225-kW AC electric traction motor. “Four state-of-the-art,

amongst others, liquid-cooled IGBT-controlled traction converters make it

possible to control each wheelset individually,” Pütz said. “The power can

be supplied by various hybrid options, including a vertical pantograph for

overhead catenary during main haulage drift operation and also a horizon-

tal pantograph for side catenary operation, allowing for continuous in-line

loading The locomotive is additionally equipped with batteries, enabling it to

operate without an external power supply.”

The Kiruna locomotive came equipped with an electro-dynamic service

brake, which is powered by the traction converter and strong enough to bring

the entire train to a standstill if required. “The system can bring 1,500 mt of

un-braked train capacity from 25 km/h to a complete halt,” Pütz said. “The

electrodynamic traction technology enables the locomotive to halt briefly or

stop and start on ascending slopes without a problem.” For emergencies

and prolonged parking, the locomotive is equipped with a fail-safe spring-ap-

plied disc brake with pneumatic release.

“A highly efficient slip-and-slide protection system is used, ensuring

the optimal use of available tractive forces, depending, of course, on

the wheel-rail friction coefficient,” Pütz said. The AC traction technology

lowers maintenance costs and reduces downtime when compared to DC

systems. The locomotive can be divided into four separate modules to

facilitate transportation and assembly underground.

underground Mining: Progress

More Toward auToMaTion

Sophisticated systems improve safety and reliability

A Schalke-LKAB 108t Hybrid Loco: A Schalke locomotive hauls ore at LKAB’s Kiruna iron ore mine in Sweden.


Perfect Flow Control Focusing on smooth pump operations, KAMAT has recently redesigned

its range of 80 kW to 400 kW three-plunger pumps. An emphasis was

placed on minimizing noise and vibration, while retaining the advantages

of the earlier design. That way miners can also continue to use the KA-

MAT wear parts they have in stock at the warehouse.

In addition to the modernization of the existing product range, the

company significantly extended the range of pumps to bigger power in-

puts with the development of five-plunger pumps. Here again maintain-

ing the target of smooth operation but at bigger flows. Two Quintuplex

pumps rated at 530 kW (max.) and 800 kW (max.) named K50000M-5G

and K80000M-5G are already available. A new K120000M-5G for an im-

pressive 1,200-kW input power per pump is currently being engineered

and developed.

Modern high-production longwalls with fast cutting shearers demand

increasingly greater flows of longwall fluid. Previously, this has been

achieved by adding more and more small or mid-sized pumps, which

has led to increasingly complex pump stations. The disadvantage for

complex pumps stations is operational reliability.

A more reliable solution for high production longwalls with big flow de-

mands is to use fewer, large KAMAT pumps. Using bigger pumps means

a less complex pumping system. Logically this reflects in less probability

of failure, less service, less maintenance, etc. Using big KAMAT pumps

leads to much simpler installations, which reduce the associated hydrau-

lic and electrical components. In most cases it also eliminates the need

for suction boost pumps. The pump station is simpler and as such much

more reliable.

For longwall operations, the K50000M-5G delivers 640 l/min at 420

bar or 763 l/min at 360 bar. The K80000M-5G delivers 1,185 /min at

420 bar or 1,360 l/min at 375 bar. This means that the longwall can be

powered by only one or two pumps.

Big pumps producing big flows increase the demand for flow control.

Thus, KAMAT also launched a new range of fail-safe smooth-acting un-

loading valves for flows up to 1,500 l/min per pump at 500 bar (max).

Since the experience with the lifetime of the solid ceramic plungers

used for KAMAT pumps have been so positive, the recently introduced

wear-resistant ceramic inner parts of the KAMAT unloader increase the

liftetime of the wearing parts in the valve significantly.

An unloading valve has to act quickly to control and limit the pres-

sure in the delivery line to the face reliably. This requirement leads to

pressure shocks in the hydraulic system—increasingly with bigger flows.

Just as it pioneered the big flow pumps in coal mines, KAMAT has been

pioneering the introduction of variable speed drives (VSDs) for longwall

pump stations. Numerous KAMAT installations in the world prove the

fact that driving a longwall pump with a VSD-drive significantly reduc-

es service necessity and increases availability impressively. The VSD

eliminates pressure shocks by adjusting the pumps drive speed to the

flow demand of the longwall without the need for the unloader valve to

switch. In periods of high demand, the pump operates at full speed and

flow. If the demand is dropping, the speed of the pump is slowed down

and adjusted to the need of the face.

The range of controllability of the speed of a KAMAT pump is unique:

typically the pump is able to be slowed down to 20% of the nominal

speed and flow, in some cases even down to 10%. Running a K50000-

5G to supply a face at the typical 350-380 bar with a VSD-driven motor

thus allows a flow spread of 640 l/min at full speed down to 130 l/min

without the need to switch the unloader valve—and without the need for

a booster pump.

For years, the now-closed Kellingley Colliery in the U.K. operated its

longwall on a single K50055M-5G delivering 640 l/min on a VSD-drive,

without a booster pump. This is the simplest and easiest way to run a

longwall, according to KAMAT. The big pumps have a surprisingly small

footprint and are still relatively easy to handle underground. Systems

built with the K80000M-5G with even higher flow, will not be wider than

1,600 mm.

One VSD driven pump is enough to ensure any flow demand of the

face. The use of only one VSD-drive in the system also reduces capital

investment in the system. Should the longwall maximum flow require

the installation of more pumps, these can be driven directly on line thus

delivering nominal flow at full speed. While the longwall flow adjustments

are managed by the VSD-driven pump, precisely to the demand of the

face.

Modern KAMAT-systems are equipped with one to three big pumps

without booster pumps, controlled by a single VFD-drive. Unproductive

stand-by capacities decrease or are eliminated. The system has high

availability, minimal maintenance requirements, servicing well the needs

of the highest producing modern longwalls. Together with KamDos, the

automatic emulsion-quality measuring and dosing system, KAMAT of-

fers their longwall pump station to meet all increasing demands of mod-

ern high-output longwalls internationally.

The 530-kW KAMAT K50000M-5G Quintuplex pump delivers 640 l/min

at 420 bars for longwall operations.

Next Generation Hoisting TechnologyUnderground coal and hard rock mines differ in many ways. Whereas hoist-

ing from 3,000 m or more is required in some metallic ore mines, the demand

for high capacities is largely driven by the coal industry. In the long history of

mining, SIEMAG TECBERG has often introduced cutting-edge technology

by advancing design and development of hoisting.

Now, in addition to the increasing demands, the industry is embracing

new social responsibility policies with much more emphasis on work-

place safety and working conditions. Technology can be used to isolate

the miner from danger. For hoist applications, traditional guards and

isolation techniques are no longer adequate and innovations such as

mechanical rope handling equipment and higher levels of safety integrity

in the equipment design are required.

“Energy utilization is optimized nowadays using AC drives and highly

efficient converters,” said Detlef Scheppe, executive vice president for

the hoisting technology business unit at SIEMAG TECBERG. “Friction

winders can be further optimized by using the innovation of an integrated

motor built into the winder drum. Its high mechanical rigidity supports an

optimized motor design apart from being a very compact solution with

several benefits to foundation and hoisting tower construction.”


For Huize, a 1,500-m-deep lead and zinc mine in the Yunnan prov-

ince, Tianjin SIEMAG TECBERG Machinery Co. Ltd. will provide one of

the deepest ore mines in China with a 5-m, six-rope floor-mounted hoist.

“In the Chinese mining industry, revamping and upgrades are getting

more into the focus of customers as they intend to enlarge their pro-

duction capacities and increase the overall safety standards,” Scheppe

said. These local projects can be served with the establishment of SIE-

MAG TECBERG in Wuqing.

When extending the life of underground mines and adopting more

stringent safety protocols, higher ventilation and cooling capacities will

be required. With the patented Pressure Exchange System (PES) for

underground air conditioning with centralized water cooling systems,

SIEMAG TECBERG said it provides the technology for the most effi-

cient systems.

“SIEMAG TECBERG has taken appropriate actions of realization

and verification of the performance and safety for hoisting plants. This

includes the review of automation and hydraulic designs by qualified

independent expert organizations to meet SIL 2 or SIL 3, depending

on the risk analysis for the function in question. A typical system would

include safety circuits, sensors, dual-channel hoist monitor (s-EHMU),

motor isolation, closed-loop brake control, hydraulics and calipers, all

certified individually and in combination.

SIEMAG TECBERG delivers solutions by meeting customer’s expec-

tations of the OEM to take hoisting system responsibility. This is based

on products that have proven to meet the high standards set by unique

experience gained in the group worldwide and successfully extending

the expertise of an automation and drive system integrator providing

total solutions. The Kure copper mine in Turkey is the latest reference

where SIEMAG TECBERG has provided such a solution including the

electrical, automation, safety and shaft signaling systems.

January 2015 marked a major milestone for a hoist system upgrade

at a mine in Canada’s Saskatchewan Province. Installation and commis-

sioning was completed for its new SIEMAG TECBERG ground-mount-

ed 12-MW Koepe hoist. This new mega-hoist, one of the world’s largest,

is a modern system capable of handling almost 1,800 mt/h.

Several years in advance, the mine targeted a massive production

rate increase, which required replacement of their aging tower-mount-

ed hoisting system. The new solution required the use of 50-mt skips

operating at more than 20 m/s and a total suspended hoist system load

of nearly 300 mt.

To tackle this aggressive goal, SIEMAG TECBERG custom-de-

signed a 5.5-m diameter, six-rope Koepe hoist directly connected to

dual 6,000 kW AC motors. The new hoist features many industry-lead-

ing SIEMAG TECBERG hoist technology innovations:

• BG 850 slide bearings with hydrostatic and hydrodynamic pressure

system;

• BE200 brake elements specifically designed and manufactured for

mine hoist duty; and

• Four-channel closed-loop brake system with constant deceleration

rate under all operating conditions.

The multiyear project required diligent and flexible project man-

agement in all phases of the project. SIEMAG TECBERG’s initial role

included hoist design, manufacturing, quality assurance, engineering

review, factory acceptance testing, shipment and controlled-environ-

ment long-term storage. Extensive site work followed for SIEMAG

TECBERG hoist specialists and their subcontractors to install and com-

mission the hoist. The work was completed safely and complied with

rigorous QA and QC requirements. Final commissioning culminated in

dynamic brake testing of descending 50-mt skips above 20 m/s. This

world-class hoisting system continues to meet expectations.

Hybrid Personnel CarrierFor more than 20 years, the MinCa (Mining Car) personnel carrier, manu-

factured by Hermann Paus Maschinenfabrik, has been a popular choice

for transporting miners to the working face. It is a front-steered, all-wheel-

drive transport vehicle designed specifically for use in underground mines.

In addition to its large Paus Minca 18A, the company has also developed a

smaller, battery-powered unit (the Paus Minca 5.1) and it has also worked

with Draeger to develop the new MRV 9000 mine rescue vehicle (See Mine

Rescue, p. 54).

The Paus Minca 18A is a versatile vehicle which can be adapted to

the most diverse requirements. A maneuverable and robust vehicle with

a payload of 4 metric tons (mt), it is specially built to handle extreme mine

conditions and can navigate headings as small as 3.7- x 3.7-m. Powered

by a water-cooled engine with a hydrostatic drive, the vehicle’s suspension

provides good ground clearance and the best comfort for the driver and pas-

sengers. Even with difficult road conditions or extreme inclines, the Minca

reaches a maximum speed of 30 km/h.

The newest generation of the MinCa is based on the same proven con-

cepts. With its compact dimensions (3,998- x 1,725-mm) and a payload of

1.2 mt, the MinCa 5.1 is ideal for narrow conditions. The fully suspended

chassis guarantees a comfortable ride on any road conditions. What sets

the smaller unit apart from the others is the three drive concepts that are

available in one platform: battery, diesel and hybrid.

The Minca 5.1 can be assembled with an 85-kW diesel engine and the

traditional hydrostatic drive. The hybrid generates 50 kW with an electric

drive and a range of approximately 12 hours. The third version is a fully

electric engine generating 50 kW and a range of about three to four hours,

which will be extended in the near future.

Paus launched the MinCa 5.1 at bauma 2016 in Munich. “The new

Minca 5.1 personnel carrier is based on the same successful experi-

ence we have had with the Minca 18,” aid Franz-Josef Paus, managing

director, Hermann Paus Maschinenfabrik. “We now have three versions

based on the same platform, the inexpensive diesel-powered model, a

battery-powered unit and a hybrid version, which is battery-powered with

a small range-extending diesel backup. It is just enough to get the ma-

chine back from the remote parts of the mine at a reduced speed.”

The Minca 5.1 is a simple, yet rugged system with a relatively

inexpensive price tag. “Mines buy vehicles from other manufactur-

ers, such as Toyota, Isuzu, etc., and they start out cheaper, but

once they add the ROPS and mine-duty upgrades, the price has

doubled,” Paus said. “Some mines buy 15 or 20 Toyotas per year

and they last two years or so; it’s part of their budget. Then there

are some mines that buy vehicles, such as the Minca, that last for

10 years.

Paus is also working on battery-powered LHD, which will be

launched later this year. “Customers have been asking for more bat-

tery-powered equipment and they have the infrastructure to support

it. They do not want the diesel emissions and the noise underground

and we understand,” Paus said.

The same system powering the Minca 5.1, which is 50 kW,

would work well for small LHD, Paus explained. The drivelines

are essentially the same. Paus is undecided at this point about

the range-extending diesel for the LHD. “There is room for it, but we

could also fill that space with more batteries,” Paus said. LHDs would

have a more limited range based on where they are working and how

they are used.

At the recent hoist installation for the Hongqinghe coal mine in China

(above), SIEMAG TECBERG provided safety improvements that includ-

ed automation and signaling systems.


As mining operations develop, the underground workings extend farther

from the shaft or portal and become more complex as they continue to

expand. Travel distances and times increase, which also complicates

rescue efforts. “Safety is one of our core values. It drives everything within

our business. As a result, alternative methods of performing a mine res-

cue needed to be considered,” said Markus Uchtenhagen, mine rescue

project manager for Goldcorp, one of the world’s leading gold producers.

“Current breathing apparatus’ durations and physical human limitations

do not allow for these increased work time required to respond to some of

the farthest reaches of our operations.” To extend the useable work time

of the current breathing apparatus, a mine rescue vehicle, the MRV 9000,

was developed in cooperation with Dr . This vehicle allows rescuers

to travel in a contaminated environment, while still maintaining full use of

their breathing apparatus capacity for on-site missions.

“Our mission at Dräger was to develop and design a mine rescue

vehicle specifically for mine rescue teams to use in the 21st century,”

said Dräger’s Global Business Development Manager Kent Armstrong.

“Dräger listened carefully to the needs of Goldcorp and the design for

their requirements and we were able to mutually come to an agreement

on a vehicle that could be used for mine rescue. We were able to partner

with the vehicle manufacturer Paus to design and build a mine rescue

vehicle for mine rescue teams to be used today and in the future.”

The Dräger MRV 9000 is built on the platform of Paus Minca 18A,

a versatile vehicle that can be adapted to the most diverse customer

requirements. The maneuverable and robust vehicle with a payload of

2 metric ton (mt) is specially built for the extreme requirements in diffi-

cult and narrow mine conditions and with a turnaround circle of 3.7 m.

A water-cooled engine with hydrostatic and hydrodynamic drive, per-

manent all-wheel drive and special suspension of the axles with good

ground clearance provide the highest possible driving comfort for the

mine rescue team. Even in difficult road conditions or extreme inclines,

the chassis reaches a maximum speed of 30 km/h. Using Paus’ expertise

in building mine-duty vehicles, the Dräger MRV 9000 is designed as an

economic, safe and reliable transport vehicle for the mining sector.

The MRV allows mine rescuers to travel to and from the incident and it

provides safe and clean breathing air and in a climate-controlled environ-

ment. The breathing air supply system is supplied via stored compressed

air cylinders. To provide a safe breathing atmosphere, both the driver’s

cabin and cassette are supplied with positive-pressure, air-purging sys-

tems. These systems are independent of the ambient air and can be

flushed up to three times. Therefore, the closed-circuit self-contained

breathing apparatus does not need to be donned during transition,

extending the mission time of mine rescue teams.

During the rescue mission with activated closed-circuit self-contained

breathing apparatus, the air flow in the MRV 9000 can be reduced manu-

ally to suit the air supply for the remaining personnel on board via the air

panels and saves resources for the return trip.

The driver’s cabin offers enough space for two persons, and the rear of

the vehicle for an additional seven people. The ergonomically designed

seats provide room for rescuers to wear breathing apparatus while being

fully restrained. Additionally, the rear of the vehicle contains an area to

allow for a basket stretcher to lay flat.

The air conditioning system enhances the safety level for the pas-

sengers. It filters humidity and protects mine rescue teams from over-

heating. Communication between the driver’s cabin and the cassette

is available via an integrated communication system. The external-

ly mounted front and rear thermal imaging cameras, as well as gas

monitoring equipment, feed information to the driver’s cabin and rear

cassette via the screens located inside the vehicle so that the occu-

pants can monitor all aspects of the external environment.

Surface Drills Used to Rescue Chinese

For 36 days, hundreds of rescue workers fought for the lives of numerous

buried miners in a gypsum mine in the Shandong province of eastern

China. On January 29, four of them were eventually

new equiPMenT reCoVers injured

Miners and Frees The TraPPed

Success begins with getting rescue teams to the action quickly and safely

Dräger’s mine rescue vehicle can transport teams to the action underground and safely remove the injured miners.


saved through a vertical emergency shaft, thanks to drilling rigs from

Bauer Maschinen Group.

The disaster in the gypsum mine, which buried 28 miners, occurred on

December 25, 2015. Eleven of them were rescued immediately, though

one died during the accident. Thirteen miners are still missing. Four min-

ers were able to escape to an enclosed space and signaled from there

that they were alive. During the very first days after the collapse of the

mine, a small supply hole was drilled so that food and clothing could be

supplied.

The necessary rescue equipment was also sent straight to the mine.

The most important system was a deep rotary drilling rig, the Prakla

RB-T 90, which was designed and built in Germany a few years ago

specifically for Chinese mine collapses; six machines were delivered.

The concept was developed in the Bauer Equipment segment. No

low-loader is required; instead, the unit is constructed on a trailer with four

axles and only needs a tractor rig. This means that the machine can be

put into operation quickly.

The China Rescue Organization holds the units at various locations in

China in standby mode. When they were required at the end of Decem-

ber, the drilling rig was dispatched for immediate use after an entire year

on standby.

Two additional Bauer units were also in operation to drill the emergen-

cy shaft, a BG 26 and a BG 38. With these, pre-drilled holes were bored,

before the RB-T 90 rig drilled down more than 200 m. The difficult nature

of the geology posed a large technical challenge for the rescue mission,

as the ground was very unstable due to the various layers of material,

consistencies, water inflow and sinkholes. At first, the hole could not be

stabilized and in the end, casings had to be used to support the hole.

A large team from Bauer was in operation, which also included many

specialists from Schrobenhausen, who were already involved in the

development of the RB-T 90 deep drilling rig. Bauer continuously mon-

itored the operations during the whole action. “We are proud that, thanks

to our modern machines, we are in a position to offer crucial assistance in

such difficult situations and also that the Prakla RB-T 90 passed its acid

test,” said Dieter Stetter, managing director for Bauer Maschinen GmbH.

On January 29, four miners were eventually saved through a vertical

emergency shaft drilled by the PRAKLA RB-T 90 deep drilling rig.

The PRAKLA RB-T 90 deep drilling rig (foreground) and two additional drills, a BG 26 and a BG 38 (background), werer used to drill rescue holes

at a gypsum mine in China.


surFaCe Mining: MoVing More roCk

saFely and CosT eFFeCTiVely

Selecting the proper primary loading tool and haulage method could be the key to success

The people who visit bauma, Expomin and MINExpo this year will surely

marvel over the massive mining equipment on display. Few will realize,

however, that these pieces of equipment are expected to perform at

the same optimum level as their smaller counterparts. With the large

loading tools and the haul trucks, reliability is extra important. Having a

shovel or a couple of haul trucks down for even a shift can be a costly

proposition.

These large pieces of equipment also rely on a host of support equip-

ment. With conventional mining processes, dozers clear the bench for

the shovels, while front-end loaders keep the loading area clean, reduc-

ing tire damage on the trucks. Sometimes those same loaders can be

the primary loading tool. Likewise, drills punch holes into the bench so

that crews can load and detonate blasts to fragment the rock formation.

Others are looking beyond conventional load-and-haul strategies to

more continuous material handling methods, such as in-pit crushing and

conveying (IPCC). These systems could also be used in connection with

continuous mining systems, such as surface miners and bucketwheel

excavators.

Liebherr Launches New Excavator and DozerWith an extensive range of equipment for loading, hauling and support,

Liebherr is the leading German equipment manufacturer for large scale

surface mining equipment. The mining business has partnered with the

company for half a century, allowing it to build a solid reputation for the

development and production of world-class excavators, haul trucks and

other ancilllary equipment.

A classic example is the recently announced R 9200, which combines

tradition with innovative thinking, to overcome any challenge, accroding

to Liebherr. The R 9200 was built to complement the company’s broad

range of mining class excavators. Equipped with a 12.5-m3 bucket, the

company said it offers sustainable performance while delivering peak

fuel burn efficiency, even in the most challenging conditions. The exca-

vator is a pass match for 140-metric-ton (mt) payload haul trucks.

The R 9200 is available in backhoe and face shovel configuration and

is fitted with the company’s advanced bucket and GET solution. The buck-

et has been engineered to deliver superior digging performance and high

fill factors, according to Liebherr. This new excavator is powered by the

Cummins QSK38 diesel engine that complies with USA/EPA Tier 2 or 4i

exhaust emission limits and has a rated output of 810 kW (1,086 hp). The

cutting-edge cab of the R 9200 provides the operator with a panoramic

view of their operation, which leads to efficient truck loading and safe

machine positioning. The R 9200 integrates an advanced electronic pi-

loting control system, which is both intuitive and versatile.

The Liebherr R 9200 excavator is equipped with the Litronic Plus

system, an intelligent power management system that enhances elec-

trical, mechanical and hydraulic power distribution. Combined with a

closed-loop hydraulic swing circuit, this class-leading system means the

Liebherr Aerial: The Liebherr R 9200 loads a 140-mt haul truck with its 12.5-m3 bucket.


Liebherr Dozer: Liebherr’s PR 776 crawler tractor pushes more than 18 m3 of rock.

R 9200 cycles faster and consumes less fuel without sacrifice. Efficiency

is further enhanced through the use of on-demand cooling control for

both water and oil. The independent cooling circuits eliminate parasitic

loss while diverting power to the attachment. By eliminating heat, the R

9200’s components operate at their most efficient temperature; efficien-

cy leads to lower cost and a longer life.

The R 9200 is designed with service simplicity in mind. Extended

service intervals and purposeful system layouts make the R 9200 easy

to service; minimizing downtime and lowering operating costs. Acces-

sibility of the upper structure is of key note, a powered 45° stairway

directs the maintainer to the centralized major service points, which can

be quickly and easily reached from this single-level service platform.

The engine, too, is surrounded by wide platforms leading to effortless

and safe access to the maintainer.

Liebherr, in consultation with its mining partners, consistently sets the

standard for advanced equipment design and technology. Specifically

designed for extreme mining conditions, the R 9200’s outstanding reli-

ability and easy serviceability provides maximum uptime. The R 9200 is

built on a 50-year foundation that combines experience with innovative

thinking, world-class engineering and manufacturing excellence.

Liebherr also recently unveiled the new PR776 crawler tractor, which is

powered by a Liebherr 12-cylinder diesel engine developing 565 kW (768

hp). The dozer has a maximum operating weight of 74 mt and is equipped

with blade capacities of 18 m3 (semi-U blade) or 22 m3 (U blade).

The modern drive concept of the new PR 776 offers an extremely

efficient and safe operation to customers. A new feature in this machine

class is the infinitely variable hydrostatic travel drive, which is used

for all crawler tractors from Liebherr. Another advantage of the mod-

ern drive concept is the optimization of pressure flow. Hydraulic servo

pressure is based on demand according to the task. If, for example,

the full feed of pressure supply is not required when operating, this is

automatically returned.

The ECO function is standard for all Liebherr Generation 6 crawler

tractors, including the new PR 776. It allows operators to choose be-

tween high performance and maximum efficiency. The ECO control

system enables greater travel drive efficiency in light to medium op-

erations, and also provides greater fuel savings.

The proactive power control is another innovation of the sixth

generation crawler tractors. Internal engine and external machine

parameters are recorded, such as the current deflection of the joy-

stick. If required, the engine power is automatically increased for a

brief period based on the current requirement. As well as respond-

ing more rapidly, the machines offer a significant increase in per-

formance potential and pulling power and a higher reverse speed.

Liebherr custom engineers integral equipment solutions. The in-

telligent Liebherr engine management system combined with the Li-

ebherr Power Efficiency System and the hydrostatic driveline allows

Liebherr to master and optimize all equipment systems and process-

es to maintain constant engine speed, increase overall machine ef-

ficiency and reduce fuel consumption of the PR776. Differentiating

Liebherr’s travel drive concept from other drive concepts available

on the market, with which the engine speed fluctuates sharply during

operation.

All of these measures lead to significantly lower fuel consumption

than the industry standard with similar pushing performance.

Another key advantage of hydrostatically powered crawlers when

working in restricted spaces is the excellent maneuverability with

continuous power to both tracks.

With an optional GPS navigation system, the work progress and the

surrounding area can be visualized, increasing machine productivity

and minimizing operator stress and strain.

Pendulum-mounted guide wheels and track rollers ensure excellent

chain traction and significantly reduce equipment vibration.


New Engine Improves Blasthole Drill PerformanceAt the Wharf gold mine in South Dakota, excavators are in constant

motion. Large haul trucks rumble up and down the spiraling hauls of

the open-pit mine, transporting tons of rock to be processed to recover

tiny gold particles. Overall mine production capacity is 3 million tons per

year. All that hard work pays off in the end, however. For 2015, gold

production at Wharf mine is estimated to be 90,000 oz.

With so much important work to be done, every piece of mining

equipment must be ready to perform. That includes the heavy-duty

machinery that starts off the mining process at each new level of the

pit—the blasthole drill rig. The Wharf mine relies on an Atlas Copco

DM45, equipped with the first MTU Series 1600 mining engine put in

service in North America.

Equipped with crawler pads, the rig moves into position atop the

mine’s bench. A 40-ft mast houses a carousel-type drill pipe changer

that is designed to drill a hole to depths of up to 175 ft. With a bit load

force of up to 45,000 lb, the DM45 produces a hole approximately 9-in.

wide. A sample of the earth is taken from each hole to determine if any

precious metals are present.

Then, using sophisticated GPS positioning, the DM45 moves on to

the next hole, creating a grid-like blast pattern.

After the pattern drilled, the holes are filled with a blasting agent and

detonated. The blast reduces the bench to rubble. The excavators and

haul trucks scoop up the rock and ore and transport it for processing.

For the Atlas Copco DM45 blasthole drill rig, the hard work at Wharf

mine never stops. The machine is in operation six days a week. Mine

operators estimate that the machine will perform 6,000 hours of work

this year.

To meet the extreme demands of surface mining, along with U.S. En-

vironmental Protection Agency (EPA) Tier 4 emissions standards that

went into effect in North America in January 2015, Atlas Copco turned

to MTU. “We teamed up with Atlas Copco and carefully reviewed the

DM45’s performance requirements. It had to meet the most demand-

ing loads—drilling large diameter, deep holes through hard rock at an ex-

tremely high rate,” said Roger Rymarz, application engineer, MTU America.

“Performance requirements are only part of determining the ‘best fit’ MTU

engine for a demanding application. Other factors also need to be consid-

ered—engine displacement, available options, time before overhaul, fuel

burn, overall engine size and weight, to name a few.”

The team decided the new 10V Series 1600 engine was the perfect

fit for the DM45 blasthole drill. “We worked closely with Atlas Copco to

assure a seamless installation, from the initial 3D design to final testing,”

Rymarz said.

The Series 1600 for power generation applications was introduced

in 2009 and subsequently followed by versions for railcars, locomo-

tives, agricultural and forestry vehicles, construction machinery, and

now, mining machines. This marks the first time the mining engine has

been used in North America. The implementation and testing of the new

10-cylinder Series 1600 mining engine took nearly a year to complete.

The engine was installed in June 2014. After more testing, it was deliv-

ered to the Wharf mine site in July 2014.

“There are many advantages of the Series 1600 for mining—low life-

cycle costs, fuel-efficiency, reliability and durability,” said Mark Bennett,

senior manager of global mining accounts, MTU America. “In a drill op-

eration, cost is measured in dollars per foot drilled at specific diameters.

It’s extremely important to mine operations like Wharf that the engine

stays productive.”

Uptime is crucial at the Wharf mine. Since these machines start the

process on each new level of the mine, a problem brings the whole

operation to a halt. For a mine like Wharf that produces one of the most

precious metals on earth, downtime leads directly to lost revenue.

“Atlas Copco was drawn to MTU’s excellent track record of providing

reliable engines,” said Bennett. “The Series 1600 was a perfect fit since

it meets Tier 4 emissions requirements without exhaust gas after-treat

The blasthole drill (above) at the Wharf mine is equipped with the first MTU Series 1600 engine put into service in North America.


Liebherr Aerial: The Liebherr R 9200 loads a 140-mt haul truck with its 12.5-m3 bucket.

ment.” Starting in January 2015, off-highway engines in North America were

subject to EPA Tier 4 emissions standards.

The Series 1600 is Atlas Copco’s first Tier 4 final engine. The Series 1600 en-

gines meet Tier 4 regulations without exhaust gas after-treatment. The innovative

engine is designed for state-of-the-art diesel combustion. Its technology package

includes exhaust gas recirculation (EGR), a high-pressure common rail fuel injec-

tion system and two-stage turbocharging, all of which enable combustion with very

low oxides of nitrogen (NOx) and particulate matter.

As the industry’s only Tier 4-capable engine without after-treatment in its class,

the Series 1600 has no particulate filter, no diesel exhaust fluid, no SCR catalytic

muffler. This makes the maintenance needs lower compared to engines with af-

ter-treatment systems. Installation is easier, as well. MTU has ensured that the

engine’s EGR components are integrated in a very compact way so the size of the

engine and the exhaust piping are not significantly affected.

The compact size of the Series 1600 made it easier for Atlas Copco to integrate

the engine into its blasthole drill rigs. “For Atlas Copco, no after-treatment greatly

reduces engineering costs. For the customer, it means lower operating costs and

less downtime compared to engines that use after-treatment,” said Bennett.

Fuel consumption is also optimized as a result of the Series 1600 technologies,

such as common rail fuel injection and two-stage regulated turbocharging. While

the engine is still in its testing phase, fuel economy statistics are not available yet.

The operators of the Series 1600-powered DM45 at Wharf mine are positive

about the new engine, too. Considering the long hours the machine is in operation,

engine noise can be an issue. Hydraulic pumps and air compressors run tirelessly.

Fortunately, the advanced technology of the Series 1600, along with Atlas Copco’s

noticeably quieter.

The Series 1600 represents the latest in MTU technology. Engineered for the

future, the engine is ready to meet the demands of tighter emissions regulations

without complicated modifications. Any operation that powers their machinery us-

ing these engines stands to benefit from MTU’s forward-thinking engine concept.

Atlas Copco has struck gold with the Tier 4-capable Series 1600. So far, the

Wharf mine’s blasthole drill has reached 3,000 hours of operation and it’s still going

strong. After a year of testing, updates and calibrations, the engine is ready for

widespread production. In June 2015, the Wharf mine received a second DM45

equipped with the Series 1600. Soon, other mining sites in North America will put

the Series 1600 engines to work.

Maximizing Coal Recovery

by Minimizing Fines Most coal mines measure the particle size distribution (PSD) of their plant feed

to obtain information about the suitability of the feed for their process, especially

regarding the fines content. But few mines know where these fines come from ex-

actly, and few still actually measure the fines content at the face to compare it to the

plant feed data and to optimize the processes in between—although optimizing the

fines content of the run-of-mine (RoM) coal offers numerous savings and benefits.

The breakage of coal occurs throughout the process chain, from extraction at

the face to the point where it is used. Some of this breakage is intentional, e.g.,

extraction and crushing, and some is unwanted, occurring when the coal is trans-

ported, stockpiled, sized or washed. Generally, breakage behavior greatly depends

on the geology, but mining technology offers a chance to affect the amount of

fines generated along the process chain. It is of the utmost importance to use this

chance and reduce the level of fines to the greatest possible extent.

has conducted several large-scale field tests on material degradation

recently. It was found that surface miners offer significant advantages when it

comes to reducing fines.

Surface miners are crawler-mounted mining machines with a rotating cutting

drum for rock penetration mounted at the center of gravity. This ensures that the

full machine weight of the miner can be transformed into rock penetration force.

The cutting drum transfers the material onto a conveyor belt from which it is directly

loaded onto a dump truck.

The Wirtgen surface miner mines layer by individual layer down to the designat-

ed depth. The cutting depth can vary according to the seam thickness. Even seams

as thin as 10 cm can be mined and precisely separated from the interburden layers

above and below it.

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links, vehicles, personnel and fuel. BEUMER off ers an

economical, effi cient and environmental alternative –

long-distance overland conveying. This gives you a dedicated,

around-the-clock transport link at the fraction of the cost

of infrastructure development. The reduced noise and air

pollution minimises environmental impact and improves

personnel safety. Add to that a high degree of design fl exi bility

and customisation and you can see why overland conveying

makes a big diff erence to operational effi ciency and

environmental protection.

For more information, visit www.beumergroup.com

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Wirtgen’s 4200 SM surface miner (above), cuts and crushes the rock

with a special cutting drum and loads it into haul trucks in a single

pass via conveyor system. Wirtgen is the only manufacturer that can

offer a performance range up to 3,000 mt/h with direct loading by

conveyor belt.

In recent years, Wirtgen has conducted several large-scale field

tests on particle size distribution and material degradation. Coal and

sedimentary ore from eight different pits were analyzed to obtain their

particle size distribution. Almost 8,000 metric tons (mt) of material were

screened to compare the material produced by Wirtgen surface miners

and conventional mining methods.

In one coal mine, Wirtgen surface miners are operating alongside

dozers that employ the conventional rip-and-stack method. In view of

the current coal prices, the mine was optimizing every step of the op-

eration. This included optimizing the process for target size material,

enabling most of the material to be processed in the cheaper coarse

circuit of the processing plant. They also were keen on reducing crush-

ing costs.

The test proved the suitability of the surface miner for this kind of

operation once more: The machine delivered coal with a lower fines

level and more target size material than the conventional dozer rip-and-

stack method.

In fact, out of the 1,500 mt/h of coal delivered from the dozer to the

processing plant, 225 mt/h are fines (less than 2 mm). The surface miner

generated 185 mt/h of fines for an equal amount of coal. This means that

22% less coal has to be washed in the fines circuit and can be washed in

the cheaper coarse circuit. Looking at the material measuring less than

1 mm, the plant processes 33% less fine material when working with

coal produced by the surface miner.

The surface miner delivers more than 70% target size coal (2–40

mm), while the dozer ranges at less than 58%. Additional savings are

generated in the crushing stage: only 17% of the material coming from

the surface miner has to be crushed, as opposed to more than 26%

when processing ripped coal. This will also result in more fines that have

to be processed.

Another trial location was a sedimentary ore deposit that is mined us-

ing surface miners and the conventional drill-and-blast method. There,

the surface miner was able to continually feed material where the less

than 1-mm size fraction was as low as 15% to the processing plant. The

normal plant feed (includes material of drill-and-blast and surface miner

operation) contained 25% and more fines (less than 1 mm).

Re-handling contributes significantly to material degradation. Simu-

lating the re-handle, Wirtgen conducted a study to establish the amount

of material degradation that does occur. For simulation purposes, 80 mt

of material were loaded by a wheel loader and run through a screening

plant several times.

With every throughput, the amount of fine material increased signifi-

cantly. During five test cycles in coal, the amount of material less than

4 mm increased from 19% to 26%, representing an increase of 34%. A

similar result was found with sedimentary ore: the fine fraction increased

by 24% during five test cycles.

None of the steps in this re-handling simulation (loading, transport to

the screen deck, sizing on the screen deck itself) involves the high mate-

rial stress levels that would be induced, for example, by a dozer moving

on stockpiled material. Nevertheless, significant material degradation

was measured during the simulation. One can assume that the material

degradation that takes place during stockpiling results in an even higher

increase of the fine fractions.

Keeping in mind that even this kind of “soft” re-handling causes sig-

nificant material degradation and that a lot of re-handling steps occur

all throughout the coal production chain, it is important to minimize the

number of re-handling steps. What is more, every re-handling step itself

results in additional costs. This is where Wirtgen surface miners offer a

two-fold advantage: Material mined with a surface miner has not been

blasted, but cut out of the ground by the rotating cutting drum, thus the

level of fines is already low. But as the material is loaded straight onto a

truck, re-handling is kept to a minimum and thus the level of fines stays

as low as possible.

Looking at the complete mining operation, using a surface miner

simplifies mining operation and reduces the number of process steps,

resulting in immediate cost savings.

Operating a Wirtgen surface miner will reduce the quantity of active

equipment required to load a ton of coal by streamlining the mining process.

Furthermore, it will simplify the interdependence of process steps in mining

operation, reducing costly time losses between the individual process steps.

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The blasthole drill (above) at the Wharf mine is equipped with the first MTU Series 1600 engine put into service in North America.

Mines try to reduce dilution or the amount of waste rock entering the

production stream in the pit. After all, tailings storage is a cost, and in

some cases, an environmental liability. The object is to leave as much

barren rock in the pit as possible, but working with an excavator and

truck has its limitations when it comes to quality control. Once the ore

(or coal) reaches the plant feed, it’s now the plant’s responsibility to

safely recover the most minerals, cost effectively.

Economies of scale are well understood in the mining business. Ordi-

narily, the larger the process stream, the more minerals are recovered.

Availability is key. Oftentimes, water and power present a problem. Wa-

ter is used for several processes. The plants are powered by electricity,

which can be expensive in the remote parts of the world where most

mines operate, and the mines usually have either too much water or not

enough. Both situations are less than ideal.

Iron Ore Grinding in BrazilDuring October 2015, Loesche celebrated the commissioning of a pi-

lot plant for concentrating dry iron ore, developed by New Steel. The

new facility is located in the historic mining city of Ouro Preto in the

Brazilian state of Minas Gerais. New Steel has developed a revolution-

ary new process for iron ore concentration for which the company was

recognized with the Platts Global Metals Award for Innovation in 2015.

This new process uses Loesche grinding technology and is considered

100% sustainable and unprecedented in the world.

The commissioning of the pilot plant drew a lot of interest in the

industry. High-ranking members of the mining industry, such as

Vale and Hatch, were impressed with the trailblazing advantages

of the new concept, which can produce valuable concentrate from

even low grade iron ore wastes without contaminating water and by

consuming much less electricity. Loesche provides the technically so-

phisticated grinding technology, which has been specifically developed

to suit these requirements.

At its core, the process operates with a newly designed dry mag-

netic separator, developed by New Steel. This separator offers unprec-

edented separation efficiency even in dry operation mode. To do so, the

separator has to be supplied with a ground product of a certain suitable

particle size distribution, which the Loesche mill provides consistently.

With thoughts toward sustainability and keeping costs low for cus-

tomers, Loesche recovers mills from operations that have closed and

tries to find new homes for them. During the last 6 years, the company

has refurbished and sold 22 second hand mills. All of which were pro-

cessing different raw materials.

Mineral ProCessing:

iMProVing reCoVery

Using technology, processing plants can improve safety and lower costs

Erlau AG | 73431 Aalen, Germany

SAVE YOUR TYRES USING

ERLAU TYRE PROTECTION CHAINS

TIME TO CUT YOUR TYRE COSTS!

SAVE YOUR TYRES USING

ERLAU TYRE PROTECTION CHAINS

TIME TO CUT YOUR TYRE COSTS!

110

1906 – 2016

Since 1906, Loesche GmbH has been constructing vertical roller grinding mills. Patented in 1928, the

roller grinding mill technology has been continually advanced and in the meantime is synonymous with

Loesche GmbH.

The new year 2016 will be a very special one – celebrating 110 years of Loesche’s innovative

engineering and Loesche mills around the world !

For more information please refer to: www.loesche.com.

http://www.loesche.com


Loesche recently purchased four of six mills it supplied to a power

plant in 1984 for grinding coal. The power plant, which was operated

by Electrabel Belgium, had been decommissioned in 2014. The mills,

type LM 20.2D and LM 19.2D, were well maintained. Nevertheless, the

company completely refurbished the mills and equipped them with a

new classifier customized for future technical specifications.

Loesche sells the refurbished mills with the new components for

about half the price of a new model. The pre-owned mill can also be

delivered more quickly than new mills. The availability and reliability of

the refurbished mills, according to Loesche, are equal to newly manu-

factured mills.

High-capacity Centrifugal CrushersVSI rotor centrifugal crushers, such as RSMX from BHS Sonthofen,

have been successfully used throughout the world for crushing rock,

including abrasive ores. At bauma 2016, the company presented its

new RSMX unit with a TwinDrive for the first time. The double drive

increases the throughput rate of up to 580 metric tons per hour (mt/h).

The first machine has already proved to be a success in treating gold

ores in China.

An RSMX 1222 with a drive power of 2 x 250 kW has been crushing

gold ore at a mine near Benxi City in the Chinese province of Liaoling.

It reduces granite from a 70-mm feed size up to sand with grain sizes

between 0 and 5 mm and gravel that ranges between 5 and 20 mm. The

proportion of sand is approximately 50% to 60%.

The RSMX is compact rotor with two generously dimensioned

centrifugal chambers mounted on a vertically positioned shaft. The

feed is supplied centrally from above and picked up by the two cen-

trifugal chambers on the rotor. The high circumferential speed of

the rotor (up to 70 m/s), the material in the centrifugal chambers is

accelerated toward the outside and ejected from the two discharge

openings of the rotor. The rock is primarily broken up by the direct-

ed one-off impact of each grain on a fixed, ring-shaped wall, which

either consists of an anvil ring or a stable material bed in the upper

part of the housing. An excellent cube-shaped grain is produced in

the process.

Ordinarily, the RSMX operating with one drive would process be-

tween 30 and 400 mt/h depending on the drive power, which can range

from 75 to 400 kW. Throughput and the reduction ratio depend on the

characteristics of the feed.

The mobile Loesche Ore Grinding Plant (OGP) at the New Steel pilot plant, Ouro Preto, Brazil.

An RSMX from BHS Sonthofen crushes gold ore at a mine in China.


Global challenges including lower commodity prices, stricter environ-

mental regulations and ambitious international climate change mitiga-

tion targets have put significant strain on the material handling business.

Overall, the mining market has been under financial strain for some time

and companies are now facing critical challenges in terms of profitability

and liquidity. In order to remain a market leader within the mining sector,

companies need to selectively make strategic investments to ensure

long-term success.

Increased efficiency and avoiding downtime is key to decreasing cost

per ton and thus accelerating the return on already made investments.

To reach highest levels of efficiency, the mining sector is taking a fresh

look at its material handling processes and looking for cost-effective

solutions that address labor intensive system interfaces or maintenance

intensive equipment. In prior times, process management of mines fo-

cused on partial optimization of single systems like mine planning or

advanced automation solutions. Today, customers demand seamless

integration of all subsystems and overall process optimization from mine

to the market.

Keeping in mind the difficult market conditions, ABB has developed

innovations that increase efficiency such as with gearless drives for

conveyors and process optimization with a combined stockyard man-

agement system (SYMS). These solutions can be applied to existing

systems to help material handlers get even more out of their assets.

The innovative SYMS solution is a good example of how the latest

technology can be leveraged to cost effectively manage bulk material

movement with a relatively small investment. In order to minimize the

efforts on material processing, storage and handling within the complete

material flow chain, an integrated stockyard management tool is needed

to build interfaces and interaction between the different levels—from

order fulfillment in the ERP system down to the operation of the pile or

even in the mine or plant.

Starting from the core of process optimization, ABB helps mines

increase efficiency by delivering reliable and nearly maintenance-free

gearless conveyor drives.

Nowadays, conveyors have to cover longer distances and ascend

steep gradients in increasingly remote locations and harsher tempera-

tures. At the same time, increased transport capacity requires wider

and longer belts, which in turn need higher powered conveyor drives.

The result is ever more stressed and less maintained equipment, which

leads to additional sources of error. In order to improve reliability by

eliminating possible sources of error, the latest trend is to drive convey-

or belt systems with less transfer stations.

ABB responded to this trend by developing a streamlined solution

that helps to overcome the mechanical limitations of the gearbox and

ensures reliability. The new gearless conveyor drive (GCD) with a

permanent magnet (PM) motor delivers radically higher reliability and

improved energy efficiency. In addition to the eliminated gearbox, the

permanent magnet motor for the GCD can work without a complex ex-

ternal cooling system, which avoids further system errors. Furthermore,

the product can be easily installed in new or existing conveyor drives

without complex mechanical design work.

The collateral savings of maintenance and energy costs by elimi-

nating equipment leads to a faster return on investment of operating

assets. For example, a belt conveyor system consisting of four belts and

with 12 permanent magnet motors of 1,000 kW each can save approxi-

mately $5 million over a five-year period.

This demonstrates clearly that the right strategic investments can

lead to efficiency gains in both the long and short term.

Steep-angle Conveying Solutions Lowering the cost for every ton moved is a guiding principle at thyssen-

krupp Industrial Solutions. The engineering powerhouse based in Es-

sen, Germany, recently completed its third gearless drive installation at

the Escondida mine in Chile, and additional systems are scheduled

to come online at the Las Bambas and Cuajone mines in Peru. The

company is also moving forward with equipment innovations, un-

veiling its largest gyratory crusher (the KB 63-130) along with other

crushers and sizers for the bauma event in Munich. In addition to its

plans to launch a smaller, more aggressive bucketwheel excavator

(BWE) for harder formations (See Innovations, p. xx), it also has

ideas on how to improve value throughout the mining chain with

advanced in-pit crushing and conveying (IPCC) systems.

These innovations are the results of an integration plan that be-

gan in March 2014 when the company combined two of its previ-

ously separate plant technology companies, Thyssen-Krupp Uhde

and thyssenkrupp Resource Technologies (formerly Polysius and

Fördertechnik) to form thyssenkrupp Industrial Solutions. Today this

group is focusing on industry-specific solutions, and mining is very

important to them.

“We are supplying some key technologies for the mining busi-

ness from Germany, including IPCC systems and advanced crush-

ing stations along with the supporting network,” said Thomas Jabs,

executive vice president-mining systems for thyssenkrupp Industrial

Solutions. “These gearless drive systems have proven to be bene-

ficial for several large-scale mining operations. We also have some

exciting R&D projects that we will roll out in the near future.”

The engineers at thyssenkrupp see haul trucks, and truck-shovel

mining to a lesser extent, as inefficient. They would like to either

shorten the haul distance or eliminate it entirely and move to contin-

uous mining if possible.

“In the current market, mines are not increasing capacity. They

are looking to maintain current levels while trying to improve the ef-

ficiency of existing systems,” said Detlef Papajewski, thyssenkrupp

vice president of mineral processing. “There is still a lot of room

for improvement as far as efficiency, especially in the area of ore and

waste haulage. Crushing systems and conveyors, especially high-angle

conveyors, offer some innovative solutions.”

In the IPCC world, there are two types of systems: fully and semimobile.

Thyssenkrupp is the only company that can supply all the components:

the crusher, the crusher plant and the conveying systems. “The primary

loading tool dumps directly into the fully mobile system, which is mount-

ed on crawlers, essentially eliminating haul trucks,” Papajewski said.

“On the semimobile systems, haul trucks dump into gyratory crushers.

We have supplied 30 semimobile plants in the last six to seven years.

We are clearly the world market leaders.” If a mine decides to install a

semimobile crushing station at the onset and then 10 years later de-

cides to move it, Papajewski explained, the cost is not that great.

MaTerial handling: where The

CosT Per Ton really MaTTers

Potential investments that help miners

make the most of existing assets


Today, almost every mine is evaluating at least the option of adding

a fully or semimobile crushing system to reduce truck haulage by

50% or maybe even to zero, Jabs explained. “When you consider all

of different factors, such as labor costs, CO2 emissions and safety is-

sues, miners have realized the value in reducing the haul distance,”

Jabs said. “With the amount of diesel fuel, tires and engines being

handled, some operations look more like storage tank sites and ser-

vice centers than mines.”

If the electrical power is available, conveyors are a much more

cost effective means of moving bulk materials. They can cross great

distances effectively, but large inclines and declines increase the

tension of the system. “The biggest risk in the past, when running

an 8,000- to 10,000-mt/h conveyor uphill, was the gear set,” Pa-

pajewski said. “It was the critical link that was failing more often

in high-horsepower applications and gearless drives eliminate that

risk.” Already several of the new large mining operations coming

online in Latin America have installed long gearless conveyor drives

with thyssenkrupp’s help.

The company is now looking to make a similar leap with steep

angle conveying. Peter Börsting, thyssenkrupp’s R&D coordi-

nator for technology and innovation in mining, discussed the

company’s inclined conveyor concepts. “Three years ago, we

unveiled an incline conveyor with two skips running on steel

structure mounted to the slope of the pit wall,” Börsting said.

“We have now taken that a step further, attaching the system to

a rope structure. It lowers the capacity a bit, but the system is

now independent from the slope wall at the pit bottom, allowing

a smooth transition to the loading point. This is a more balanced,

energy-efficient system. The stability of the slope wall is no lon-

ger an issue—an important factor for areas prone to seismic ac-

tivity—and it can follow the pit if it goes deeper.”

Many mines are evaluating steep angle conveyors. These skip

systems can climb 65° to 70°, Börsting explained, while the high-

est angle for a conventional conveyor is 15°-18° depending on

the materials. “Our colleagues in the materials handling division

have the cable and crane technology and we knew we could apply it

to open-pit mining,” Börsting said.

Thyssenkrupp has three high-angle conveying systems: the

skip-way system for medium and large mines; the integrated skip

conveyor for large capacity and high lifts; and the MegaPipe Con-

veyor, which closes the inclination gap between the conventional

and the skip conveyors. The MegaPipe was co-developed between

thyssenkrupp, Contitech and Siemens. “We are working on other

alternatives as well,” Börsting said. “Steep angle conveying is going

to happen and it will be a game changer.”

Looking toward the future, Papajewski said thyssenkrupp is look-

ing at applications for Big Data. “There is a huge amount of data and,

when you understand all the connections, it can be used to make

improvements in efficiency,” Papajewski said.

As an example, Papajewski explained that all of thyssenkrupp’s

gyratory crushers are now being supplied with the thyssenkrupp Gy-

ramatic and Telesystem. “The operators can switch it off if they like,”

he said. “Usually they switch it on when they need help and we can

support them wherever they are in the world.”

“Our aim is to be as close to the client as possible not only with

dealers but also with engineering,” Papajewski said. “The HPGR

business is a great example. We are the largest supplier and we

have six large service centers to refurbish HPGRs around the world.

We have huge machines to perform this maintenance and repair

work, but we can also perform maintenance on crushing and grind-

ing systems.” This thinking ties directly to the reorganization of its

business.

Today, tthyssenkrupp is much more market focused. “The in-

tegration of the plant business combined the strengths of market

leaders and we are now capitalizing on engineering synergies,” Jabs

said. “The great thing about miners is they love to build these massive

operations. Whether they are looking to build or improve existing opera-

tions, we are ready to support them.”

The engineers at thyssenkrupp Industrial Solutions are looking at three steep angle conveying solutions to reduce truck haulage in open-pit mines.

Efficient Drive Systems

for Belt Conveyors

Over the last quarter-century, most large belt conveyors operating

underground in Germany have been equipped with TT linear booster

drives. They offer a range of clear benefits. In new systems, the use

of Voith TT Linear Booster Drives avoids transfer points, protecting

the belt and resulting in a longer service life. In many cases and

depending on reserves, TT drives can improve the capacity of old-

er conventional conveyors—without needing to change the existing

drive or replace the belt. They lower belt rating requirements and,

in many cases, enable the use of textile belts in operations where,

under normal conditions, a steel cord belt would be necessary. This,

in turn, eases splicing, handling, and repairs, therefore reducing the run-

ning cost of the overall system. The ability to operate with a lower-rated

belt translates to lower running cost, as well as reduced investment in

the belt—which is the single most expensive component.

A few months ago Voith delivered two TT linear booster drives to the

German mine, Prosper Haniel, operated by Ruhrkohle AG (RAG). The

mine produces 3 million metric tons per year (mt/y) of coal. The belt con-

veyor H2 is 1,270 m long and has a conveying capacity of 2,000 mt/h.

The former steel-cord conveyor belt showed serious damages months


before the scheduled overhaul. To have the system running without long

lasting downtimes, a first TT linear booster drive was installed during the

regular conveying to reduce the tensile forces on the belt and thereby

extend its lifetime. The second TT linear booster drive was also installed

during the regular conveying in the mine. Now the strain on the belt

could again be reduced so that the existing belt (type: ST5000) could

be replaced by a less-expensive and low-maintenance textile belt (type:

PVG2000).

The TT Linear Booster Drive is equipped with a head and tail station,

which is integrated into the actual belt. The drive is assembled directly

within the current conveyor system. The top belt of the existing conveyor

system (carrying belt) rests upon the top belt of the introduced TT drive

(pushing belt). The TT drive leads the tensile force linearly through a

friction lock in the belt. Belt tensile forces are significantly lower than

with standard solutions.

TT drives are ideally suited for use with high-power drift conveyors

and overland conveyors. While conventional systems often need to

rely on steel cord belts with large drive units, a system with TT drives

can reduce belt rating requirements. This often enables usage of more

cost-effective textile belts and smaller drive units; e.g., pulleys, gearbox-

es, standard-size motors. In addition, the space required for the head

drive is considerably smaller, which is an important aspect in under-

ground mining.

Voith TurboBelt TT Linear Booster Drives are also used to increase

the performance of existing belt conveyors. When it becomes necessary

to expand conveying capacity for operational reasons, a performance

improvement is required. This means either increasing belt rating (i.e., a

new belt) and/or strengthening the drive station in conventional plants.

By implementing TT drives, this problem can be economically solved.

The existing drives and belt remain unchanged, while TT drives can be

assembled and deployed quickly for reduced downtime. This solution

avoids the need for intermediate transfer points, resulting in reduced

stress and less dust. In coal haulage pathways further benefits are sim-

ple shortening and lengthening of conveyors without having to exchange

the standard equipment.

TT Linear Booster Drives provide benefits when used with medium,

long or inclining belt conveyors. They provide maximum return when

used with belt conveyors of 800 m or longer, as well as with inclining

or declining belt conveyors, independent of length. In terms of installed

base, approximately 150 conveyor systems have been equipped with TT

drives, equivalent to about 300 km of aggregate length, with roughly 250

drive stations delivered.

Voith engineering teams design and develop optimized solutions for

every belt conveyor system. Depending on the operation, these can in-

clude TT Linear Booster Drives and conventional configurations. Voith

also provides complete project management services and supervision of

on-site construction and testing.

The TT Linear Buster Drive from Voith can increase conveyor performance.

Celebrating Milestones in

Conveying TechnologyThis year BEUMER is celebrating 80 years of customized and efficient

conveyor solutions. Based in Beckum, the company has established a

respected position in the world market. “We can only achieve a high

level of customer satisfaction and a sustainable, successful market pres-

ence when the whole team is involved in the corporate strategy in the

long term,” said Dr. Christoph Beumer, chairman and CEO of BEUMER

Group. He has been managing the family business since 2000, now in

the third generation.

In 1935, a 33-year-old Bernhard Beumer started his first work day

as an entrepreneur with four employees. Until then, he had been

working for a conveying technology company in Essen. One of his

most important seed assets, aside from his courage and determina-

tion, was the experience he gained as a repair mechanic for con-

veying technology, working in the mining industry in the Ruhr area

before completing his degree in engineering. He deicded to step out

on his own.

A considerable step toward the success of Beumer conveying

technology was his development of the idler with labyrinth seal. The

founder of the company had this innovation patented and integrated

it further into other products. The company continued to grow, em-

ploying about 100 people at the outbreak of World War II.

After completing studies in mechanical engineering, his son, Ber-

nhard Beumer Jr., followed in his footsteps. He worked at his father’s

side for 18 years and took over the company after his father’s death

in 1981. In the field of conveying technology, he particularly pursued

the development of bucket elevators. He quickly realized that a chain

as a traction element was too heavy. The company had a wealth of

experience in belt conveying technology. This gave Bernhard Beum-

er the idea of using a belt as the traction element for bucket eleva-

tors. The company perfected the system. By the mid-1980s, the sup-

plier had installed about 100 systems altogether, in 2007 and 2008

they were installing about 450 bucket elevators per year, worldwide.

Besides the product development in the field of conveying tech-

nology, Bernhard Beumer Jr. also continued the initial development

of loading systems and set the company on a decisive path of global-

ization, founding companies in Brazil, USA and Asia.

In the 1960s, Beumer laid the foundation for curved belt conveying

systems. The first theoretical designs on the market were from the

company’s department for research and development. Today, this

group is one of the technological leaders for these systems, either

as troughed belt conveyors with open design or as pipe conveyors.

One particularly impressive reference project is the 12.5-km-long

troughed belt conveyor in the Chinese province of Sichuan, which

was put into operation in 2008 and currently conveys about 2,200

tons of limestone from the quarry to the cement plant. Its routing

features several vertical and horizontal curves. The system travers-

es 1.5 km of water surface and extensive bamboo forests, and can

overcome height distances of up to 100 m. For the same project, the

Beumer Group has now been awarded the contract to supply and

install another conveyor of similar size, and the customer is already

planning a third expansion phase.

Meanwhile, the company also pursued other handling systems

unrelated to bulk materials, such as palletizer and high-capacity

packaging systems.

Since 2000, Dr.-Ing. Christoph Beumer, the founder’s grandson,

has been managing the company. “The success is primarily due to

the familial spirit. We have consistently held to our motto, ‘we are


looking for the long-term success, and not for the

short-term profit,’” he said. BEUMER ensures the

long-term success of the company through man-

ageable growth, a large range of products and

a global market presence. BEUMER machines

and systems are in use all around the world. The

group consistently pursues its globalization, by

setting up local group companies, and even lo-

cal production facilities in China and Thailand.

The result: the company has exhibited extremely

stable organic growth over the last several years.

Undeterred by the impending financial and glob-

al economic crisis, Beumer took over the Danish

sortation technology specialist Crisplant in 2009,

followed later by companies in India, USA and

Belgium. Hundreds of thousands of suitcases ev-

ery day pass through Beumer baggage systems

at airports in Frankfurt, London, Beijing, Singa-

pore and other locations worldwide. Thousands of

packages traverse conveyor belts supplied by the

intralogistics specialist at parcel centers operat-

ed by Hermes, GeoPost, UPS and FedEx. With

its acquisition of Enexco Technologies in India, a

manufacturer of grinding systems and packaging

machines for the cement industry, BEUMER has

reinforced its presence in vital markets and simul-

taneously and systematically expanded its portfolio,

without abandoning its traditional segments.

Dr. Christoph Beumer is chairman and CEO of

BEUMER Group based in Beckum. He is the third

generation to manage the family business.

Beumer pipe conveyors provide perfect adaptability

to local conditions.


Primary and Secondary SizersWith hundreds of complete systems, as well as individual machines,

having been supplied to clients all over the world, Tenova TAKRAF is

a key supplier of equipment and systems for open-pit mining and bulk

handling. Recently, TAKRAF enhanced its product portfolio with the ad-

dition of sizer equipment, which now enables the company to integrate

its own crushing machines into complete mining solutions for its clients.

TAKRAF offers standardized primary and secondary sizers for var-

ious crushing applications. The primary sizer product range accepts

feed sizes from 2.5 m to 4 m with a throughput of up to 10,000 metric

tons per hour (mt/h); the secondary sizer range accepts feed sizes from

2 m to 4 m with a throughput of up to 3,500 mt/h. Both sizer product

ranges are suitable for the comminution of all material types, from stan-

dard to most challenging.

During the sizer’s initial development, TAKRAF paid close attention

to attributes such as ease of maintenance, reduced downtime and long

equipment service life. Some of the innovative solutions adopted in-

clude the quick and easy changing of crushing segments, as well as the

use of advanced wear-resistant materials such as hard-faced segments

and tungsten picks. Other innovative solutions include an inching drive

for roll maintenance, which increases safety significantly, a heavy-duty

drivetrain system, as well as adopting an efficient oil lubrication system

with a view to greater environmental sustainability.

The TAKRAF sizer model type TCS 12.16 will be installed at the test

facility in Germany.

BWEs Engineered for Harder FormationsThe engineers at thyssenkrupp have announced two smaller BWEs

(the Barracuda and Mine Shark) that can be used for harder formations

(compressive strengths to 50 megaPascals). Traditionally, BWEs work well

in soft formations with compressive strengths well below 20 MPa, mining

mostly lignite, oil sands, phosphate, etc., that run 5 MPa to 10 MPa.

To convert the BWEs to cutting from digging, improvements have

been made to both the bucket and the teeth, as well as to the power

train and the steel structure. Thyssenkrupp’s R&D teams determined

that a larger number of stronger teeth and buckets, combined with more

cutting torque, would be key for the extraction process. Of course, com-

bining the extraction and loading process into a single machine gives

the BWE a great advantage and it eliminates the need for blasting.

These new BWEs are expected to produce more than 3,000 mt/h.

“These news BWEs could handle some of the hard coals found

in Australia, Indonesia and India,” said Thomas Jabs, executive vice

president, thyssenkrupp. “We are trying to incorporate this BWE cutting

technology into machines that are smaller, more flexible and easier to

operate than the traditional BWE.”

Solids Handling PumpsMany gold operations process ore through autogenous grinding mills.

Ground ore is classified by hydrocyclone separators and ball mills re-

grind the coarse material. Sized materials are sent through a flotation

process where the sulfide minerals are separated and concentrated

(flotation concentrates) and sent to a thickener/filter press circuit prior

to roasting.

The thickener/filter press circuit reduces the amount of water in the

flotation concentrate and is typically pumped using horizontal centrif-

ugal pumps. The use of this type of pump can be counter-productive

because water must be added on the thickener cone bottom to assist

transport by the pump. Also, gland seal water must be added to the

centrifugal pumps in the two pumping stages. In total, the volume of

water introduced back into the thickened underflow fed to the filter press

can be increased by as much as 25%.

One plant replaced their centrifugal thickener underflow pumps with

ABEL series EM 100 electromechanical diaphragm pumps. Cone water

additions and gland seal water were no longer required thus helping the

process substantially. Also the maintenance costs associated with the

thickener underflow pumps was greatly reduced.

This same plant’s filter press feed pumps had also originally been

centrifugal slurry pumps. Wear on the centrifugal pumps was consider-

able with pump wet ends wearing out as often as every two weeks, and

costing as much as $20,000 each time. Downtime and lost production

mounted with each repeated occurrence.

To mitigate the problem, the centrifugal filter press feed pumps were

supplemented by ABEL series HMD-G-80-1000 piston-diaphragm

pumps. The ABEL pumps employ a hydraulically balanced elastomer-

ic diaphragm, ideal for moving abrasive slurry at higher pressures. By

working in parallel, the centrifugal pump “fast-fills” the filter press at

lower pressures, then hands over consolidation of the press cycle to

the ABEL. The resulting pump maintenance costs and down-time were

greatly reduced. Filter cake quality was improved due to the positive

displacement action of the ABEL pump.

In early 2011, the same plant added another process train of

thickener and filter press to increase the Hydraulic Diaphragm Pump

HMD-G-80-1000 gold production. ABEL EM 100 pumps were specified

for thickener underflow and ABEL HMD-G-80-1000 pumps were speci-

fied for filter press feed duty.

The ABEL HM series pumps are hydraulically-driven, piston-diaphragm

pumps. Reciprocating motion of the piston moves an elastomeric di-

aphragm by means of a hydraulic end. Ball checks and seats on the

product end are available in various materials. This characteristic de-

sign allows the pump to transfer abrasive slurry or sludge at pressure

up to 1,450 psi (10 MPa). The ABEL EM series pumps as used on the

thickener underflow have a similar wet end construction as the HM.

innoVaTions: an assorTMenT oF

equiPMenT For Mines and Mills


ABEL’s HMD Pump for Filter Press Feed.

Powered Handling and Lifting EquipmentJD Neuhaus (JDN) has been designing and manufacturing handling

equipment for more than 250 years, and pioneered the use of com-

pressed air for powering handling equipment in the early 1950s. The

latter development ensured that their lifting and pulling equipment was

suitable for use in hazardous areas and environments where there was

a risk of explosion.

The company’s hoists and hoisting equipment, which now also in-

clude optional hydraulic-powered operation, are used worldwide in all

major heavy industries. With a range that covers lift capacities from

250 kg up to a full 100 metric tons (mt), JDN air hoists offer reliable,

high performance. Some of the typical advantages offered as standard

include robust construction with a low-maintenance compact design.

The units are relatively lightweight and easy to handle. They operate

at low pressures (4 or 6 bar). The hoists can precisely position loads

when using the relevant controls. The Ex-rated hoists ensure the

highest levels of safety for operating in potentially explosive or oth-

er dangerous atmospheres that can occur in coal mining and other

environments.

Over the years, JDN has developed many purpose designed prod-

ucts for use in specific industries, such as mining, which is acknowl-

edged as one of the toughest fields. The hoists can be found operating

in multiple mining applications, such as pulling longwall roof supports,

lifting and lowering on stationary platforms, in combination with mono-

rails for equipment transport, lifting and lowering of objects in vertical

shafts.

JDN’s M series air hoists have been designed specifically for mining

and other underground applications. They operate off a 4-bar pressure

and can be supplied in lift capacities of 1, 2, 3 and 6 mt. Twin chain

pulls are provided for alternate working conditions and all hoists fea-

ture a top hook mounting to accommodate oblique or horizontal pulling

of loads. These products can be equipped with two optional control

systems for single or two-handed operation.

The DS system, which is designed for the two-handed operation,

has compressed air connected to the hand-control valve. A built-in

pressure regulator prevents hoist overload in the event of inadmissibly

high air pressure. An oiler, situated directly at the hoist motor, is op-

erated from the controller housing to ensure the oil flow automatically

ceases when the hoist stops. The operating air immediately initiates

the motor when the hand lever is activated. This lever is spring loaded

and returns automatically to zero position when released. This forced

release also serves as an emergency stop.

The Profi TI series hoists are also suitable for use underground.

Traverse trolleys for overhead monorail operation are also available

for lift ratings up to 20 mt (max). These trolleys can be supplied for

manual, reel chain and motorized traverse movements, with rack and

pinion drives also available.

Recently a Profi TI hoist with 37-mt lifting capacity was used to safe-

ly and successfully handle an assembled 1,000-m pipeline string. This

involved the connection of individual pipeline sections, each 8 m long,

to create a completed string weighing 30 mt that had to be positioned

within a mining shaft.

JDN’s Profi TI air hoist can lift 37 mt.

Conveyor Components & AccessoriesSpecializing in the supply of components for belt conveyors for all

kinds of bulk handling industries, Schulte Strathaus, located in Unna,

Germany, recently introduced STARCLEAN scrapers, which are de-

signed to help conveyors operate more efficiently. The object was to

provide optimum cleaning result from the first to the last minute of the

blade’s lifespan. This is achieved using the TWIST-SWING feature

that ensures that every blade adapts to the belt and provides longest

lifespans. Being experts in the field of belt cleaning, Schulte Strathaus

knows that conveyor downtime is unacceptable and, when scraper

blades are worn, the replacement should be carried out in a minimum

of time. All STARCLEAN scrapers provide a plug-in foot and are insert-

ed into the shaft without the use of any tools. This feature paired with

the one-touch quick-tensioning devices ensures that the maintenance

can be carried out within minutes.

STARCLEAN scrapers have a plug-in feature to quickly change scrap-

er blades.


VdMa

adVerTisers

index

Abel GmbH & Co KG . . . . . . . . . . . . . . 29

Beumer Group GmbH & Co.KG . . . . . . . 28

Erlau AG . . . . . . . . . . . . . . . . . . . . . . . 30

Kamat Pumpen GmbH & Co. KG . . . . 12

Liebherr Holding GmbH . . . . . . . . . . . . 17

Loesche . . . . . . . . . . . . . . . . . . . . . . . . 31

Voith GmbH . . . . . . . . . . . . . . . . . . . . . 19

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