mining mining m

Raw Coal Loading

and Belt Conveyer
System at the
Nochten Opencast
Mine
Industrial Solutions and Services
mining mining mining mining mining mi
Your Success is Our Goal
Translated from
Braunkohle Surface Mining 50
No. 2 March/April 1998
Trans Tech Publication
Clausthal Zellerfeld, Germany
Authors:
Dr. Werner Daus, LAUBAG, Senftenberg
S. Krber, Reichwalde
Norbert Becker, Siemens AG, Erlangen
An indispensable requirement of the
Lignite Planning Procedure (1992 - 1994)
was the removal of the old coal loading
facility from the town of Mhlrose. In
accordance with the Regional Planning
Act the Lignite Plan called for this re-
location in terms of a target , i.e. a
planned measure with significance for
regional planning which was to be
implemented by 1996.
Owing to the massive investments
undertaken by LAUBAG a target
amendment procedure with respect to
the loading facility relocation was applied
for in 1995 and approved for 1998.
The investment funds were released in
May 1996, and a contract for the work
was awarded to Siemens AG (as prime
contractor) in November 1996.
With regard to the construction of the
facility a maintenance contract was
entered into with Siemens. The work had
to be completed in an extremely short
period of time.
2.1 Funding and rationalization
objectives
Based on operational experience and new
technical capabilities, a new conveying
line and bunker complex were to be
designed featuring state-of-the-art hand-
ling technology and equipment. In view
of the cost situation and the existing plant
and equipment, the design concept
incorporated a sensible combination of
the existing technical basis and promising
innovative technology.
The belt conveyors were taken from
existing stock at Nochten mine. The
stacker-reclaimer (KSS 10000) required
and the train loading facility were relocated
from the neighboring Reichwalde open-
cast mine. Just two belt distributors had
to be built from new in the storage area
in order to avoid disruptions in winter. This
decision allowed the investment funds
made available to the company to be
concentrated on technical innovations
with great rationalization potential. A short
payback period was to be achieved
through the following effects:
Energy savings
Rational deployment of operator's
personnel
Reduction of maintenance costs by
economical plant and equipment
operation
Wear-oriented maintenance on the
basis of guaranteed diagnostic values.
A New Conveying and Loading System
Based on Drives Controlled
by Frequency Converter
In November 1997, twenty-five years after production commenced
at Nochten opencast mine, a new conveying system, a new train
loading facility, and the first stage of a coal handling area were
taken into operation. The new conveyor system is only slightly
longer than the old one, but cuts rail transportation distances
by 16.5 km. This means that the newly erected part of Boxberg
power station can be supplied with coal direct by belt conveyor
(Fig. 1).
2. The complex requirements
for relocation of the Nochten
coal loading plant
2
Fig. 1
Old belt conveyor, 12.5 km long,
installed output 17.4 MW
(2-4 mining machines depending on
the customers quality requirements)
Mhlrose loading facility
Old railway transportation distance
21 km
New belt conveyor, 13.4 km installed output
23.2 MW
New coal loading facility and stockpiles
New railway transportation distance
4.5 km
Boxberg power station
2
3
4
5
6
7
1
In order to obtain planning permission for
the facility, a 'target modification proce-
dure' for the Lignite Plan for Nochten had
to be initiated. Particularly stringent require-
ments were laid down with regard to
emission control. The following solutions
were proposed, accepted, and eventually
put into effect:
Relocation of the facility near the power
station and removal of bunkers in the
power station
Particulate matter protection by means
of extensive cleaning installations
Noise protection by enclosure of drive
equipment, noise-reduced rollers,
reduced belt speed, erection of a
building around the loading facility,
and creation of a noise-protection
embankment.
2.2 Reducing operating costs with
the new facility
2.2.1 Belt conveyor
Significant potential for cutting costs was
identified in the shape of a variable-speed
belt conveyor.
In all the LAUBAG opencast mines, the
workings under the F60 cross-pit spreader
were greatly oversized and serviced by a
number of small excavators. Essentially,
there were three reasons for this:
Compensation for the front-end working
method of the F60 by the block working
method of the mining machines to
guarantee as far as possible the uniform
and uninterrupted operation of the
overburden transporter
Changing quality modes of operation in
conjunction with a high belt conveyor
utilization rate owing to excess machine
capacity
Compensation for machine downtime.
These reserves were necessary to
maintain supplies up to 1992/1993.
Declining coal sales and changing
requirements with regard to raw coal
quality gave rise to new conditions.
Maximum loading of the belt conveyor at
all times was achieved by way of machine
overcapacity.
The aim is to run the system with as little
operator intervention as possible. To
achieve this the frequently changing work
locations must be able to go into operation
centrally without any delay. Once the
operator's team has switched from one
piece of equipment to another the neces-
sary monitoring, operating and control
functions are to be secured. This allows
a single team to look after more than one
item of equipment.
In this concept, the coal is to be recovered
by the KSS (when the mine has stopped
working) and loaded without the need for
a central control point. The process control
systems required can be switched to the
KSS in this case.
2.2.3 Process control system
Multimedia technology makes it easier
to operate the transportation and bunker
system with a minimum number of
personnel while at the same time guaran-
teeing operational safety, system avail-
ability, and operating performance.
The process instrumentation and control
levels have been combined on the basis
of advanced communication technology.
A redundant, open-protocol, broadband
multiplex system, OTN (Open Transport
Network), transmits all signals from the
instrumentation and control system,
including emergency shutdown, plant
status monitoring equipment (diagnosis),
communications equipment (telephones,
command units) and video equipment
along fiber optic cables.
Yet the positive effects of high belt
conveyor utilization met with a price in the
machine sector.
Thanks to variable-speed control, which is
oriented around an optimum belt conveyor
load cross-section, flexible optimization is
achieved for a defined control range
without the need to maintain reserves.
The greatest benefits from this technical
measure are anticipated in the areas of
technology management, wear minimi-
zation, energy conservation, and the
reduction of emissions. For this reason,
this discussion will look at the technical
design, operation and the initial results of
the measure separately and in more detail
at Point 3.
2.2.2 Coal handling plant
The new coal handling plant (Fig. 2) had
to be designed to fulfill two tasks:
To supply the refurbished Boxberg power
station (installed output = 2 x 500 MW)
and, if applicable, other customers with
raw lignite via a train loading facility
with maintenance of separate stocks
(stockpile A has a capacity of 80,000 t).
This stockpile is to be served by a
stacker-reclaimer (KSS 10000)
To supply the newly erected part of
Boxberg power station via a system of
permanent stockpiling (stockpiles B and
C each have a capacity of 100,000 t).
Stockpile B is also to be built up by the
KSS 10000; stockpile C will eventually
be served by an extended belt conveyor
and a stacker. Stockpile C and the
associated conveying equipment will
go into operation in a second stage not
until after1999.
Stockpiles B and C are combined working
and reserve stockpiles and will be ope-
rated under these conditions by the
customer (VEAG). To this end a number of
special legal and organizational agree-
ments are to be reached. The automatic
operation of the three major system
components (KSS 1000, belt-to-train
loading facility and, at a later date, a
stacker) was considered an essential
means of optimising the process.
Fig. 2
Coal storage area
3
SIMOVERT Cabinets
Radio-based functions such as belt-stop
and data radio (monitoring of mining
machines and quality assurance system)
have also been set up. Complex proce-
dures for conventional belt-stop
monitoring systems (push-buttons, horn,
wiring) have been replaced by a simple
radio-linked structure. The open, operator-
controlled, realtime systems and
standards used here allow the system to
be expanded and adapted to changing
needs and conditions without the need
for major additional expense.
The entire system is controlled from
Nochten mine's central control point by
a single operator. This control point also
includes the maintenance interface (plant
and equipment diagnostics), an important
prerequisite for communications between
system and process engineers.
The savings achieved in this area are
difficult to quantify. They will, however,
provide valuable development impetus
for operations, organization and mainte-
nance in the next few years.
2.2.4 Maintenance
Owing to the very short project planning
and completion time LAUBAG decided
to award the entire construction works
to a main contractor. The most impressive
concept for this work was put forward
by Siemens. It was awarded the contract
and, together with a number of subcon-
tractors, built the facility in just seven
months.
A major element of the contractual agree-
ments was the link between plant con-
struction and subsequent maintenance
work. The idea was to ensure that the
plant builder was interested in a lowest
cost maintenance system right from the
outset.
A further consideration, which pointed
in favor of a complex third-party main-
tenance system, was the possibility of
combining operating experience with the
know-how possessed by plant builders
and manufacturers. With this synthesis
the aim is to attain a new quality in the
field of professional maintenance work
and sustained progress in all aspects of
maintenance management.
In accordance with this objective new
jobs are being created that reflect this
development and are backed by the latest
technical equipment in order to maintain
the synergy between technical develop-
ment and organization. An important
instrument in this respect is the technical
diagnostics system. In diagnosis, we
distinguish between operational and
expanded diagnosis.
In short, operational diagnosis means
the use of product-specific software
tools from a central point for selectively
accessing major, technologically complex
components (e.g. converter, decentralized
field bus networks etc.) throughout the
facility in order to record, analyze and, if
necessary, correct their current status.
Expanded diagnosis means the fore-
sighted analysis of the process and status
of plant and equipment to detect any
deviations from the intended status at an
early date.
Here, time patterns (operating hours,
changeover procedures, parameter
changes), capacity-related parameters
(e.g. rates of utilization, torque and tem-
perature curves), status data (e.g. vibration
characteristics, wear values) and external
influences are of major importance.
The principal idea behind this concept is
the gathering of data from various sources,
e.g. the automation system, the status
detection system and the results of in-
spections, and putting it together with the
aid of intelligent, computer-based methods
to deliver effective information. This infor-
mation forms the basis for a status-oriented
system of maintenance and the associated
replacement parts management system.
Some of the outstanding characteristics
of the expanded diagnosis system are
listed below:
Highly detailed diagnosis for monitoring
of stocks by means of error pattern
detection and fuzzy logic support.
Error detection on the basis of freely-
definable error patterns.
Automatic generation of maintenance
orders.
Generation of freely-definable
characteristic values.
Universality of the information flow from
the automation and status monitoring
system via the intelligent diagnostics
system to the maintenance planning
system.
Closing the interface between the diag-
nostics and maintenance systems creates
the conditions required for status-related
maintenance operations. Here, mainte-
nance work is conducted according to
actual requirements and not, as was
previously the case, at fixed, static intervals.
This new maintenance strategy will make
a major contribution to savings on the
basis of wear-related maintenance,
enhanced organization and an improve-
ment in levels of expertise due to the
introduction of a sensible form of com-
petition between the skilled mine
personnel and the service providers.
4
Workstation for maintenance
Converyor control center
3.1 Rationale
A project involving a belt conveyor system
for the reliable transportation of defined
bulk materials is planned. A major plan-
ning aspect is the effective handling
capacity of the connected plant and
equipment. These capacities are added
together and, furnished with corres-
ponding safeguards, included in the
planning of the transportation capacity.
This gives an average theoretical volume
of material to be transported.
All subsequent calculations (e.g. drive
output, number of driven drums, angle of
belt contact, belt width, tensile strength,
tension force, steel structure etc.) are
based on this value, coupled with geo-
metric and climatic influences and with
a constant belt speed.
This approach creates a permanent
problem: the greater the difference
between the volume of material being
transported at any one time and the
theoretical formulation, the less favorable
the ratio between the cost incurred (drive
output, material) and the benefit obtained.
If the system is not used to full capacity,
potential is squandered; if the system is
overloaded, disruptions are often the
result. The margin above is determined
by a safety factor; if a downward deviation
arises, this leads to resources being
wasted.
A fluctuation round a nominal load such
as this can be tackled using a selective
mining machine control and adjustment
system. The more excavators there are,
the more complex this becomes, due to
the complex variety of parameters.
Example:
Total capacity breakdown as a result of:
Excavator malfunctions
Technology-related equipment
transportation during disc/block
replacement.
Reduction in capacity due to:
Initial cutting losses
Rotary (sickle-type) cutting losses
Subgrade/footwall excavation
Quality-related capacity assignment in
accordance with the quality assurance
system
Special excavations (overburden,
relocation etc.).
A number of investigations and tests
revealed that under the prevailing con-
ditions at Nochten mine a linked open- or
closed-loop control system for four mining
machines with the aim of achieving a
uniform volume of material being moved
is not feasible. The solution is to be found
in keeping the belt speed under constant
control, which will be explained at Point
3.3.2. Economic efficiency constitutes a
major factor when employing a belt-speed
control.
by a consortium made up of the following
companies:
Siemens (ATD Division), STAMAG
(mechanical supply of the belt conveyor
system), FAM Magdeburg (KSS stacker-
reclaimer), BEA Technische Dienste Lausitz
(KSS electrical assembly) and the
construction company Schwarze Pumpe
(construction supply), with Siemens (ATD
Division) in the role of prime contractor.
From the preparation to the trial stage,
the definition of tasks was accompanied
by a research project run by the Faculty
of Mechanical Engineering at Senftenberg
Technical College. Details of the technical
performance can be seen at Figure 3.
The belt is tensioned by motor-driven
cable winch. Depending on the capacity
requirements the belts are equipped with
a maximum of four three-phase squirrel
cage motors each driving a lower and
upper belt drum via gear units.
Fig. 3
Conveyor routing
As the electrical equipment had to be
replaced in full after 25 years of operation,
a large number of synergies arose. The
added expense of the converter solution
amounted to some 25% in comparison
with conventional systems. Besides the
question of costs, additional investigations
are to be carried out with regard to the
system's endurance properties. The
correlation between variable speed,
increased system utilization and the
wearing of major system components is
especially worthy of study. The kinetic
resistance properties of the belt under
these conditions are also in need of re-
evaluation. The start-up and run operations
are of particular importance here.
3.2 Design of the drive systems
The definition of tasks for the concept
was drafted by an interdisciplinary LAUBAG
team. The project was implemented
3. The concept behind a
variable-speed belt conveyor
Figur ?:
Dies ist ein Blindtext
und steht in keinem
Zusammenhang
900 kW
M
3~
1000 kW
1000 kW
900 kW
M
3~
1000 kW
1000 kW
900 kW
M
3~
1000 kW
1000 kW
900 kW
M
3~
1000 kW
2) 2) 2) 2)
1000 kW
4200 kVA
6/0,69/0,69 kV
1)
M
3 AC 6 kV
1) NTSCGEWu 3,6/6 kV
2x(3x95+3x50/3)
2) NSSHu-O 4x(3x95)
Fig. 4
Drive configuration
Conveyor drive 4 x 900 kW
with SIMOVERT Master Drives
Conveyor K 63, K 66
5
Bd. K66
Bd. K67
Distributor 1
+128
2 Hs-S VEAG Feeder conveyor
Bd. K72
VEAG Building
Distributor 2
As-G
Train loading Conveyors
S1 to S4
Ks-S
Bd. K71
+128
+126
+124,8
+80,7 +78,5
+49
+50
+54
Bd. K61
Bd. K62
Bd. K63 Bd. K64
Bd. K65
Belt conveyor
Bd. K61
Bd. K62
Bd. K63
Bd. K64
Bd. K65
Bd. K66
Bd. K67
Bd. K71
Bd. K72
Phase one IBN 11/1997
Phase two IBN 05/2000
Bd. K73
Bd. K74
AA(m)
1870
1720
2045
1735
870
2525
1755
665
220
114
690
BB(mm)
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
2000
Belt
P3150
P3150
St3150
St3150
St3150
St3150
St3150
St3159
St3150
St3150
St3150
P(kW)
3x900
3x900
4x900
3x900
3x900
4x900
3x900
2x630
2x630
1x630
2x630
Phase one
Phase two
The motors have the following
parameters:
P
N
= 900 kW (630 kW)
M
N
= 8665 Nm (6060 Nm);
M
K
/M
N
= 2.8 (2.6)
U
N
= 690 V
I
N
= 2 x 455 A (630 A)
n
N
= 992 min
-1
Speed adjustment range:
500 - 1000 min
-1
with constant torque
Cooling system:
self-cooling/integrated cooling system
Connection to two separate 3-phase
winding systems.
A SIMOVERT

MASTERDRIVES inverter
is connected to each of the motor.
The inverters are supplied by a common
direct-current link via two feed unit or
feed/feedback units connected in parallel
with each other.
The converter transformer is a three-
winding transformer, which means that
a 12-pulse system perturbation is
achieved. The converter transformer is
supplied in the primary circuit by a 6 kV
medium voltage unit (Fig. 4).
The drives are designed for:
Starting torque = 1.3 x Mn
Maximum running torque:
approx. 1.6 x Mn
Start-up time = 60 s
Braking time = 18 s
Creep speed = 200 min
-1
at 0.8 M
N
for
S1 operation
The inverters adjust the speed of the
drives by means of a TRANSVEKTOR
control. They are equipped with fully
digital SIMOVERT MASTERDRIVES
system components with IGBT power
transistors for connection to a motor with
two separate winding systems. Cooling
is provided by a closed-circuit cooling
system.
The braking energy occurring on shutdown
is fed back to the line supply with the aid
of a second thyristor bridge.
The technological controls consist of a
soft ramp generator for the setpoint speed
of a drive station. Each motor has its own
speed controller with adjustable load
regulation. Tachometer speed controllers
are not employed, the actual speed is
taken from the motor model.
To cushion the effect of speed fluctuations
in conjunction with two motors working
at one drive drum a speed differential
control is provided. By storage of the
most recent torque value prior to drive
shutdown and precontrol of the setpoint
rate of acceleration the torque controller
is provided with a defined precontrol value
for the next start-up operation. Uneven
load distribution caused, for example, by
unequal drive drum diameters is prevented
by a load sharing control.
All electrical equipment (6kV, 500/400 V,
converter equipment, control and monito-
ring equipment) is housed in a closed
container (9500 mm x 6300 mm L x B).
In the case of movable equipment (K61,
K62) the containers are mounted on the
drive station. At permanent items of
equipment (K63 to K66) the containers
are positioned alongside the equipment.
The technical design of the Nochten
coal belt conveyer system is documented
at [1].
3.3.1 The load-dependent belt-speed
adjustment system
Electricity consumption represents a major
cost factor when operating belt conveyor
systems and is influenced by a large
number of parameters. The effect of these
influencing factors has been looked at in
detail in the relevant specialist literature,
including [5, 6, 7, 10].
In the case of the belt conveyor system
at Nochten the task of adjusting the belt
speed according to the various quantities
to be transported so as to exploit the
available load cross-section to the greatest
possible degree was turned into reality.
This solution will be described in relation
to power consumption below.
The required drive output P
el
of a belt
conveyor, which has to be transmitted to
the materials being transported by one
or, simultaneously, by more than one drive
drum, is arrived at based on the kinetic
resistance F according to (4):
P
el
= (1/) F v (1)
v = belt speed
= efficiency of gearing and motor
The kinetic resistance F is calculated
according to DIN 22 101 in equation (2).
F = C f
RT
L(m'
R
+ (2m'
G
+ m'
L
) cos _) g
+ H m'
L
g (2)
If we put equation (2) in equation (1),
we obtain P
el
with cos = 1:
P
el
= (1/) C f
RT
L (m'
R
+ 2m'
G
) g v
+ (1/) (C f
RT
L g + H g) (m'
L
v) (3)
where
L = distance between drum centers
m'
G
= mass of material being
transported in kg/m
m'
R
= mass of idlers in kg/m
m'
L
= mass of material being
transported in kg/m
(distance load)
= conveyor gradient
H = difference in elevation
C = coefficient of length
f
RT
= coefficient of friction and
temperature
I
m
= handling capacity in kg/s
or t/h (after conversion)
g = acceleration due to gravity
K
O
= (1/) C f
RT
L (m'R + 2m'G) g
K
L
= (1/) (C f
RT
L g + H g)
I
m
= -m
L
v
Using the abbreviations K
O
, K
L
and I
m
it
is possible to write in simplification:
P
el
= K
O
v + K
L
and I
m
(4)
The lifting work (H m'
L
g) is independent
of the speed and no longer taken into
consideration below.
According to [11] and [5] f
RT
also becomes
a function of belt speed. This correlation
was demonstrated during the practical
trials.
By breaking down the drive output into a
no-load element (K
O
v) and a load element
(K
I
I
m
) the following facts become
apparent:
The no-load element is proportional to
the speed v
The load element is proportional to the
distance load m'
L
and speed v.
3.3.2 Evaluation and representation of
the initial test results
The trials delivered the correlations shown
at Figure 5.
Essentially, the theoretical principles in
accordance with equations (3) and (4)
were confirmed, see also [2, 3].
First, sufficiently significant evidence was
gathered to demonstrate a proportional
dependence between the electrical drive
output and variable load at a constant belt
speed in each case. This means that in
practice f
RT
can be assumed to be virtually
constant at a fixed temperature and
constant belt speed in each case. In
contrast, f
RT
decreases as the belt speed
drops, i.e. specific energy consumption
also decreases due to the diminishing
load K
L
.
The parameterization for the envelope
curves (1, v = v
nom
) and (2, v = 0.5 v
nom
)
was done on the basis of a performance
test conducted on the Nochten belt
conveyor system in the period between
December 11, 1997 (10 p.m.) and
December 12, 1997 (2 p.m.).
The data obtained was analyzed using
linear regression; the results for the
permanent conveyor lines K63 to K71
were grouped together to give standar-
dized mean values.
P
el
P
el
=
P
N
1,0
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
1 P
0
2 P
n
0,26
v`=0,5
(2)
(3)
0,9
0,8
0,7
0,6
v`=1
(1)
0,5
1,0
I
m

= I
m

/ I
mN
6
Fig. 5
h
The stock of values available for the
envelope curve (2, v = 0.5 v
nom
) will have
to be increased by further trials. The curve
section (3) is determined by the threshold
capacities of the conveyor lines for
downward adjusted belt speeds
(v - 0.5 ... v
nom
).
A second result is obtained from the
formation of handling capacity mean
values over various time patterns
(see Fig. 6).
During the performance test four
excavators (2 SRs I300 in the high cut,
2 ERs 710 in the low cut) were in service.
They were configured to run at maximum
output by mine manage-ment. The
maximum eight-hour output achieved in
the period between 4 a.m. and 12 noon
amounted to 40,223 t (a very high figure
in comparison).
In evaluation of the results the sliding
mean handling capacity value was
obtained by 5, 15, 30 min and 1, 2, 4, 8
hour averaging (see Fig 6.). The maximum
8 hour mean value was 4643 t/h.
The following conclusions can be drawn
from this series of measurements.
1. Attempts to continuously move along
the length of a belt the maximum
quantity of material that can be handled
according to the available belt cross-
section proved unsuccessful. The
integration time of five minutes (5 min
maximum value = 84.36%) corresponds
to the running time of a longer conveyor
(1800 m at 6.0 m/s).
These findings are to be consolidated
during long-term testing. There exists
a genuine basis for re-optimizing
the drive output in accordance with
DIN 22 101 for similar coal belt conveyor
systems.
Protection against short-term peak loads
can be provided by intermittent overload
operation (operating mode S6 in accor-
dance with EN 6000341).
2. With an integration time of less than
four hours the integrated maximum
handling capacity value lies below 50%
of potential handling capacity. As a
minimum requirement this necessitates
a belt speed adjustment range of
50 to 100% v
nom
.
Theoretically, the control range would
need to be extended downwards. A
simple co-ordination of the machines so
as not to drop below the 50% mark would
appear to make sense.
Fig. 6
100%
75
50
25
0
-25
Belt scale K65 t/h 1s Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 5min Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 15min Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 30min Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 1h Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 2h Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 4h Mean value
100%
75
50
25
0
-25
Belt scale K65 t/h 8h Mean value
Test results 11/12/97 21:30 - 12/12/97 13:00
22:00 0:00 02:00 04:00 06:00 08:00 10:00 12:00
11/12/97 12/12/97
100
75
50
25
0
100%
75%
50%
25%
Belt scale K65 (%) V (%)
4:30
12.12.1997
4:35 4:40 4:45 4:50 4:55
time (sec
5:00 5:05 5:10 5:15 5:20 5:25
Readings
100
75
50
25
0
100%
75%
50%
25%
Belt scale K65 (%) V (%)
6:30
12.12.1997
6:35 6:40 6:45 6:50 6:55
time (sec
7:00 7:05 7:10 7:15 7:20 7:25
Readings Name
max. load K 62(%)
Belt scale K65(%)
max
96.78
99.02
min
34.963
10.210
mean
72.628
0.61
0
0
Name
max. load K 62(%)
Belt scale K65(%)
max
91.653
83.59
min
27.932
8.301
mean
64.825
45.5
Fig. 7
7
3.3.3 Implementation of the
belt speed adjustment
Loading of the K61 and K62 face con-
veyors is controlled from the control point
according to the machines in use.
K61 e.g.:
1 excavator 50%nominal belt speed
2 excavators 75%nominal belt speed
3 - 4 excavators 100% nominal belt speed
The lower base value for the K62 belt is
75% of the nominal belt speed.
From belt K63 to the loading facility all
belt lines are controlled from 0.5 - 1 v
nom
according to the quantity of material being
transported.
The actual quantity of material being
transported is determined 100 m before
the point of transfer from belt K62 to belt
K63 (transfer to the permanent head belt)
by a Vegasonde sensor (made by VEGA,
measuring principle: ultrasound). The
distribution function of the data recorded
with regard to the quantity of material
transported is shown in Figure 7.
In the process the control system does
not compensate for every peak load. Short
overload peaks can be absorbed by the
conveyor system (peripheral loading and
storage in transfer chutes) [2]. Load-
dependent control is currently being
achieved as follows: the data obtained is
sent via the Vegasonde sensor to a shift
register, which is a pulse-clocked device,
and maintained as the setpoint in accor-
dance with the running time of the belt
(e.g. 15 s at v
nom
) up to the K62/K63
transfer point; smaller values are
suppressed during this time. The setpoint
value is adjusted upwards only by a later
occurring larger value.
A downward speed adjustment is
achieved by means of a gradual decele-
ration ramp (v
nom
- v
min
) in five to ten
minutes. The complete loading control
system is much more extensive and
specific than described here. Further
details can be obtained from the
documentation [1].
Figure 7 shows two distribution functions
for different load runs. For the first load
run the average quantity amplitude is
45.5%, the control attains a mean speed
of 60% v
nom
, the minimum downward
speed is limited to 50%. The limit speed
lines (red) correspond to the deceleration
ramp described above.
For the second load run the average load-
dependent belt speed is approximately
75% v
nom
.
During long-term testing mean belt
speeds of 0.68 v
nom
were achieved by
this method. With these settings up to
25 control operations occur in an hour.
Even better speed adjustment can be
achieved with steeper deceleration ramps.
However, the number of control opera-
tions increases.
At present work is being undertaken in
conjunction with Senftenberg Technical
College and the ATD Division of Siemens
to qualify these operations.
3.3.4 Energy conservation results
to date
On completion of a long-term study
electricity savings of 20% have hitherto
been demonstrated.
This figure already takes into account
converter equipment (semiconductor
valves, ventilation) losses totalling 3.5%.
The average belt speed has become
established at v
r
- 0.68 v
nom
during con-
trolled operation. The monthly energy bills
incurred so far have more than confirmed
these figures.
The 20% savings can be broken down as
follows:
Load-dependent belt speed adjustment
With an average haulage capacity of I
M
/I
N
below 50% and an average belt speed of
0.68 v
nom
the savings achieved according
to Figure 5 amount to 16%. The potential
25% savings (difference between curves
(1) and (2)) have been demonstrated during
testing under practice conditions on
several occasions (Siemens).
Savings achieved by removal of slip
resistors
Permanent slip resistors on conventional
machines are designed for approximately
4% belt slippage (s) in order to achieve
load compensation for the driving torques.
Saving:
P = s P
nom
= 3%
Removal of starting resistors on
slipring motors
A = 3 x I
2
start
R
starter
t z
With z - 2700 start-up processes/ the
energy saving amounts to 0.5%.
Acceleration energy reduction
Starting up only at v = 0.68 v
nom
yields
acceleration energy reductions of
approximately 45% (see also Point 3.5
'Effect of wear') with a drop in kinetic
energy:
(m
red
+ (m'
R
+ 2m'G + m'
L
) L) v
2
/2
m
red
reduced driving mass
m'
L
see equation (2, 3)
Related to the annual energy consumption
of all the equipment this gives a saving
of approximately 0.4%.
Start-up losses due to simultaneous
start-up of converter-controlled belt
conveyor systems
Conventional machines
(wound rotor motors consecutively with
time delay)
8
Stacker / reclaimer
Nine conveyors, each with a start-up time
of 30 s, are started up with a 20% time
overlap. This gives:
(9 x 30) 0.8 = 3.6 min
Converter-driven conveyor systems
with 5 s time delay
9 x 5 s = 0.75 min
A = 2.85 min. P hour/a z
z = number of starting operations per year
Resultant energy saving per annum =
approx. 3% due to enhanced equipment
capacity utilization on start-up (excavators
and conveyors).
Braking energy recovery
To date the braking energy has been
converted to heat; now the braking energy
is fed back to the line supply by the feed-
back power converters of the converter
drives. The braking energy is calculated
according to:
(m
red
+ (m'
R
+ 2m'G + m'
L
) L) v
2
nom/2
m
red
= rotating driving masses, other
designations as at equation (2, 3).
Savings through energy recovery per
annum approx. 0.5%.
The remaining factors of influence
when using converter drives in com-
parison with slipring motors roughly
cancel each other out
.
These include:
Line power factor converter 0.98 cos
slipring rotor 0.70
Higher transformer losses in conjunction
with converters.
Lower deterioration of motor efficiency
in conjunction with converter drives.
The additional losses due to cooling (fans,
air-conditioning units) and semiconductor
losses amount to approximately 3.5%.
3.4 Effects of load-dependent speed
adjustment on equipment status
In light of the operating experience gained
to date any initial analysis can only point
towards possible answers.
Precise findings will be obtained only on eva-
luation of long-term wear measurements.
As already demonstrated at Point 3.3, the
specific conveyor belt load per unit of length
(distance load m'
L
) increases as the belt
speed falls; see also equations (2), (3):
m'
L
= I
m
/v see also equations (5, 10).
Thus, according to equation (2) there is
also an increase in kinetic resistance F.
This clearly shows that the correlation
between the change in belt speed and
the associated effects on required
maintenance effort is to be considered
complex and not merely proportional.
Generally speaking, the degree of wear
on a belt conveyor due to friction can be
worked out on the basis of the energy
balance because:
1. Kinetic energy (friction, acceleration)
accounts for more than 90% of energy
consumption and
2. The energy savings achieved by the
reduction in speed stem exclusively
from the kinetic energy.
In qualitative terms this statement is
based on the following assumptions:
The wear caused by friction is proportional
to the generated frictional work (A
R
).
A
R
= K F ds = K F v dt (5)
A
Run
=
U
K F
U
v
U
t
U
(5.1)
A
Rger
=
g
K F
g
v
g
t
g
(5.2)
where
A
Run
= uncontrolled
A
Rger
= controlled
According to Point 3.3.2 (Fig. 5) the
following can be treated as equivalent
(both occurrences take place in the same
time):
v
g
= 0.68; v
U
= 0.68 v
nom
and
F
g
= 1.25 F
U
;
U
=
g
and t
U
= t
g
Thus, the product of (F v), which corre-
sponds to the drive output according to
Point 3.3.1, becomes an evaluation
criterion:
(F v)
ger
= 1.25 0.68 (F v)
un
= 0.85 (F v)
un
A
Rger
= 0.85 A
Run (6)
Using this approach we can calculate
that the wear to the moving components
of a belt conveyor system is reduced
on average by approximately 15% when
the average belt speed is reduced to
68% of v
nom
.
The effects of wear on components will
be dealt with below. We appreciate that
wear processes unfold in a more com-
plicated manner than that described here.
The extent and significance of belt wear
is dealt with, in particular, at [9].
3.4.1 Wear on conveyor belts and idlers
The coal belt conveyor system was
equipped with used belts and idlers. For
this reason it is difficult to make and, more
especially, prove any forecast in respect
of wear.
The kinetic resistances are of decisive
importance for belt and idler wear [10]:
Indentation rolling resistance
Vibration resistance between idler
catenaries
Grinding resistance of the material being
moved and resultant friction on belt
and, if applicable, idlers
Charging and stripping resistance
Damage caused by foreign bodies.
As already shown above, not all influencing
variables exhibit a proportional relationship
to speed.
The dependence relationships are in some
cases extremely complicated. To permit
their better estimation it is planned to
convert a part of the mine conveyor
system into a test section.
The results obtained are to be subject of
future discussion.
The basis for a 15 to 20% saving by
a reduction in speed is thus to be
demonstrated.
3.4.2 Changes in wear on the belt drums
The wear to the surface of belt drums in
relation to the speed of the belt is to be
assessed with regard to creep (elongation
of the belt due to tensile forces) and
frictional work due to contamination by
dirt. In accordance with Point 3.4 this
element of wear ought to be reduced by
approximately 15%.
The slide slip is dealt with at Point 3.5.
It is safe to say at this point that where
converter drives are used there is hardly
any slide slip worthy of note. This can be
taken as a basis of support for the wear
analysis and its projected saving of
approximately 15%.
3.4.3 Other subassemblies
Wear to the material stripping devices
In accordance with the product of
(F
Nr
V) the reduction in wear is likely to
be directly proportional to the reduction
in belt speed. A 30% reduction is consi-
dered feasible.
Wear behavior on baffle flaps and wear
plates
The reduction in belt speed in conjunction
with an inversely proportional increase in
the specific volume of material being
moved m'
L
(equation (2, 3)) causes a linear
reduction of the kinetic energy imparted
on the baffle flaps.
m (v
2
/2) - (m'
Lnom
/0.68) (0.68 v
nom
)_ =
0.68 m'
Lnom
(v
2
nom
/2)
The impact face is enlarged by a varying
parabola of trajectory. In conjunction with
more abrasive materials (sand, gravel etc.)
this can lead to additional wear. For coal
savings in the range of 20% are antici-
pated.
9
6 KV-switchgear
slip resistance (normally 3 to 4%) and a
resultant drive operation with natural
motor slack (0.5 to 0.7%) is to be rejected.
This also applies, to the same or to a
larger extent, to an alignment of the
permanent slip resistance to varying drum
diameters at nominal load.
In the case of converter drives, such load
transfer because of different drum dia-
meters cannot arise; the load compen-
sation equation between the drums
always maintains the torque at the same
load proportion.
3.5.2 The belt slip problem
Belt slide slip is caused by varying load
distribution on the drive drum (see above
and [3]) and mainly occurs at the lower
drum during the start stage when the
maximum belt tension-force relationship
T
1
/T
2
(Eytelweiner Equation) is exceeded:
T
1u
/T
2u
< e

(7)
= active friction value between belt
and drum
= drum looping angle
The reasons why slide slip occurs can be
clearly recognized in Figure 9 (arrow at
lower belt tension path). Due to the sharp
increase in starting torque (dM/dt is very
high with conventional drives), the
vibratory conveyor belt system causes
transient recovery to take place.
3.5 Reduction in dynamic forces
through use of converter-fed drives
Using converter-controlled drives produced
by Siemens (ATD Division), a completely
new drive system for largescale belt
conveyor systems has been developed
and constructed. The effects on equip-
ment system dynamics are outlined
below:
For a general understanding of the subject
the major drive system control functions
will be named first:
Speed controller (via the frequency)
for all motors
Active current differential control and
speed differential control for all the
motors working on a drive shaft
Load sharing control between upper
and lower drive drums
Load torque and acceleration precontrol
with load torque storage on belt shut-
down and
Rate setter with rate of change limitation
(first derivative of acceleration).
3.5.1 Drive characteristics
The power output of the front drive
stations is generally transmitted to the
belt by two driven belt drums. The drum
drives are provided with a semi-rigid
connection by the link formed by motor-
gear-shaft-gear. A minor amount of slip
caused by the elasticity of the gear
components (backlash and spring effect)
is contained by the active current
differential control (conventionally by
means of slip resistors). Providing a
balance between the upper and lower
drive drums is a much more complicated
affair. Stretching of the belts and diffe-
rences in belt diameter lead to con-
siderable differences in speed and thus
differences in load between the drums.
This problem is outlined at Figures 8
and 9.
Figure 8 shows two motor characteristic
curves with 4% nominal slip (slip resistors)
and a difference in drum speed of 2%
(drum diameter). As the speed of the belt
drums is the same due to the impressed
belt speed, different load distributions
arise for different drum radii.
Example according to Figure 8:
Load occurrence 1:
upper drum M
O
= 1.0 M
nom
lower drum M
U
= 0.5 M
nom
Load occurrence 2:
upper drum M
O
= 1.0 M
nom
lower drum M
U
= 0 M
nom
Similar load occurrences were recorded
by Senftenberg Technical College at the
Nochten conveyor line prior to the con-
version work (see Fig. 9).
The consequences and effects of the
facts described here regarding the
kinematics are considerable, cannot
however be further treated at this point.
From the point of view of the plant
capacity (maintenance), above all in partial
load operation, removal of the permanent
Fig. 8
10
150
125
100
75
50
25
0
M
o
t
o
r

c
u
r
r
e
n
t


[
A
]
50
40
30
20
10
0
-10
T
o
r
q
u
e

[
k
N
m
]
60
50
40
30
5 5,5 6 10 15 Time [min]
5 5,5 6 10 15 Time [min]
5 5,5 6 10 15 Time [min]
Motor current, OL
Motor current, OR
Motor current, UL
Load run 30% Load run 100%
Torque, UL
Belt tension at the KMD [kN]
Idle
upper drive (1)
lower drive (2)
T
2u
T
1u
=
.
r=2

.
n
.
r

1
>
2
>
3
; caused by strain slip, see (13)

1
=
2
(1+

2
)

1
,
2
; strain coefficient
2

.
r

n=
M/Mn
1.0
0.5
0.25
-0.25
-0.5
1% 2% 3% 4%
s%
slip
lower
drum
upper
drum
3
2
1
n
Tr
n
Tr
= 2%
Fig. 9
Starting and steady operation on ATS

1
,
2
; strain coefficient
Multi-mechanical drives for conveyors
M
o
t
o
r

c
u
r
r
e
n
t

[
A
]
250
T
e
n
s
i
o
n

[
k
N
]
150
B
e
l
t

s
p
e
e
d

[
m
/
s
]
10
225 135 9
200 120 8
175 105 7
150 90 6
125 75 5
100 60 4
75 45 3
50 30 2
25 15 1
0 0 0
2555 2560 2565 2570 2575 time [s]
Motor 2 Motor 1
According to Figure 9 (arrows), the
minimum belt tension has the effect of
minimal T
2u
, and the maximum drive torque
as T
1u
. Consequently, T
1u
/T
2u
becomes
extremely large, facilitating slide slip in
the starting process.
The relevant correlations are also illustrated
in [8] and [11].
This fact can be compensated with level
and adjusted torque increase during the
starting process. This cannot be achieved
with conventional drives, pre-tension stages
only serve to reduce the problem. Converter
drives fulfill this requirement by means of
an adapted torque control; torque transient
recovery is avoided as much as possible.
A further advantage of the implementation
of converter drives is the considerable
reduction in friction work when belt slip
occurs. With conventional units, this
generates considerable frictional heat A
R
.
A
R
= 2 - M
anf
- n - t (8)
The torque relief (slip) causes the entire
speed range from 0 to n
nom
to run up
immediately. With a controlled converter
drive this acceleration is limited to the pre-
set range (in Nochten it is 5%).
As a result, possible slip friction with
converter drives amounts to a maximum
of 5% of the slip-free work, which can
occur with slipring armatures. It therefore
becomes apparent that belt slide slip in the
starting stage of regulated converter drives
is reduced immensely.
Considerable transient belt tension, which
puts strain on the belt tightness and
positioning, also occurs during the shut-
down phase with conventional drive
systems (Fig. 10).
These processes are minimized by means
of adjusted rundown procedures with
regulated belt drives.
3.5.3 Explanation of the starting and
load characteristic curves
Converter plants are selectively started up
via predetermined start inclines (speed
over time, for Nochten 60 s:
dv/dt = constant). The starting torque is
therefore adjusted as required in accordance
with the load state. As a result the
acceleration torque
M
b
= J
ges
(d/dt) - J
ges
(1/r) - (dv/dt)
in total is reduced considerably.
With conventional drives, the starting torque
is determined by the motor characteristics
set for maximum load. In the case of
minimum load, the starting torque during
start-up is far too high, thereby putting an
unnecessary strain on the plant systems.
T = J
ges
/M
Manf
- 1/r - v
M
Manf
= motor starting torque is a set value
Previous test results bear testimony to
this fact.
Of all the starting processes which have
been evaluated, the maximum starting
torque achieved was 1.07 x M
nom
. However,
starting peak values of 1.35 x M
nom
are the
being aimed at. Starting processes with
conventional drives, in full load operation,
produce starting peak values of 1.5 x M
nom
,
the remaining starting peaks (partial load)
lie insignificantly under this value. In practice,
the difference between the torque starting
peak values (old/new) is 28%. This eva-
luation is based on the highest quarter-
hourly value for transport performance
attained during the performance test of
December 11-12, 1997:
Belt K63 0.75 M
nom
Belt K64 0.75 M
nom
Belt K65 0.85 M
nom
Belt K66 0.69 M
nom
Belt K67 0.70 M
nom
The average daily temperature was 8.5C.
If these values are converted to -20C
according to (4), the projected parameters
are moreorless confirmed. Taking the
correlations into account (see also 3.3.2),
it must be concluded that some passages
of the evaluation procedure for belt
calculation in line with DIN 22 101 must
be reconsidered for the implementation
of converter drives. This especially applies
to the determining of the safety factors
(12).
3.5.4 Effects on the maintenance of
the electrical units
Savings on electrical maintenance are
achieved with the following components:
SF6 switchgear instead of air-insulated
units
Use of encapsulated low voltage units
(MCC technology) instead of half-open
units
Use of decentralized relays instead of
centralized low voltage units
Use of sensor/actuator bus or field bus
installations instead of conventional
star-shaped wiring layouts
Use of converter technology instead of
conventional resistance control
Use of low-maintenance three-phase
induction motors instead of slipring
armatures
Use of handheld radios for deactivating
belt/stop instead of the more
complicated and conventional belt/stop
infrastructure (release cords or buttons)
Installation of switching buildings in
container construction next to the drive
station in the case of stationary belt
conveyor units (avoiding vibratory strain)
Implementation of on-site inspections
using a centrally automated diagnosis
system.
Additional expense is only incurred by the
cooling system for the converter units
(fan, cooling aggregate). In total it has
been calculated that a considerable saving
in electrotechnical maintenance require-
ments can be achieved by the concent-
rated implementation of the measures
named above, whereby the savings factor
after the introductory phase will be in the
upper half of the savings range.
11
Fig. 10 Stopping process for belt conveyor system
Stopping with masses (7|25|97 10:39)
Motor 4 Motor 3
mining mining m
mining mining mining mining mining mi
mining mining m
mining mining mining mining mining mi
The investment project "Relocation of
Coal Loading, Nochten" was realized in
the LAUBAG in 1997. This relocation was
necessary in order to comply with legal
pollution control regulations. At the same
time, shortening the rail transport distance
brought a considerable economical
advantage.
The investment requirements were to be
kept to a minimum by the use of existing
technical equipment, and attention was
to be concentrated on a promising
innovation potential. In particular, the aim
was to achieve results in
Energy saving
Efficient use of operator personnel
Reduction in maintenance requirements.
This was to be realized in four ways:
1. Energy saving by means of a speed
control or regulator throughout the
entire coal belt plant
2. Automatic stacking, reclaiming and
train-loading of coal, with low operator
requirements and safe operation.
3. Use of an advanced process control
system with low operator require-
ments, with integrated communications
structure and multimedia applications
4. Realization of a new maintenance
management system by means of
situation-relevant, diagnosis-supported
maintenance, using contractors in a
new complex manner.
These objectives were achieved to the
largest degree possible.
In particular, this article has attempted to
illustrate the technical concept and the
regulation principle, as well as the results
which have been achieved and which are
expected, of a speed-regulated belt plant.
After the theoretical investigations on
hand and initial practical experience, the
following effects of the use of converter
controlled large belt plants compared to
conventional plants are considered
possible:
Electrical power consumption:
savings of between 15% and 38%
Mechanical and electrical maintenance
expenditure:
savings in the main components of
between 10% and 30%, in the special
components savings of up to 50%
Plant construction:
reduction in the projected drive
performance by 15% to 30%, and up
to 30% of dynamic belt tension and
bearing strain.
Siemens Aktiengesellschaft
Siemens AG. All Rights Reserved
Bestell-Nr. E10001-P11-A3-V1-7600
Printed in Germany
Dispo-No.: 21662 K-No.: 28700
11D6677 TA15312X07 SD 12021.
Subject to change without prior notice
Contact
Siemens AG
Industrial Solutions and Services
Mining Technologies
P.O.Box 32 40
91050 Erlangen, Germany
Tel.: +49-9131-74 26 17
Fax: +49-9131-72 22 33
E-mail: mining@erl9.siemens.de
www.siemens.com/mining
The initial experience gained is being
implemented in the LAUBAG specification
for other projects (conveyor Tgb. Jnsch-
walde, conveyor ATS 306 Tgb. Welzow-
Sd). The total completion costs for
converter controlled drive solutions will
not be greater than those for conventional
solutions. The costs for the electrical units
will rise by 15% to 20% compared to
those for mechanical components (drive
performance, output, belt connections,
etc.).
The reports that have been presented,
and the results that have been achieved,
are to be consolidated by the accompani-
ment of further technical measurements
and back-up interpretation, in order to
develop further potential in the interest
of high economy and decisive cost-savings
in lignite mining.
This article has made concrete reference
to belt conveyor plants with raw coal; the
correlations are similar in the case of
barren rock belt conveyor plants; there
are however differences in detail. For
example the speed adjustment is more
balanced, the energy saving from the load
dependence is somewhat less (the
specific weight of overburden is greater
than that of raw coal).
Bibliography
[1] WEBER, D., KELLER, C., HALKOW, K., a.o.: Pflichtenheft
zum Project Kohlebandanlage und Kohleverladung
Nochten, Siemens AG, ATD/NPI field, April 1997.
[2] BIEGEL, P., METZING, a.o.: Untersuchungen und
Forschungsergebnisse zum Aufbau der Kohle-
bandanlage Nochten Oktober bis Dezember 1997;
Technical College Lausitz, Senftenberg, Machine
Engineering Faculty.
[3] WUSCHEK, V.: Neuartige Antriebslsung verringert
Energieaufwand bei der Kohlefrderung;
Siemens Special Edition, Issue 3/1997.
(4] ALLES, R.: Frdergut Berechnung: Continental
Gummiwerke AG Hannover, 1st Edition 1979.
[5] HAGER, M.: Entwicklungsmglichkeiten der
Gurtfrdertechnik in Tagebaubetrieben;
Braunkohle/Tagebautechnik Vol. 43 (1991),
Nos. 1-2, pp 26-31.
[6] HAGER, M. and HINTZ, A.: Einflu des Gurtlaufes
auf den Energieverbrauch von Gurtfrderanlagen;
Braunkohle/Tagebautechnik Vol. 45 (1993),
No. 9, pp 5-13.
[7] GHRING, H. and NEUGEBAUER, H.:
Bewegungswiderstnde an Gurtfrdern mit
B = 2500mm; Braunkohle/Tagebautechnik
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[9] EICKEMEIER, J.: Stand der Gurtfrdertechnik bei
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[10] GREUNE, A.: Energiesparende Auslegung von
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[11] FUNKE, H.: Dynamisches Verhalten von
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[12] LODEWIJKS, G.: Non-Linear Dynamics of Belt
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[13] GRIMMER, K-J.: Die Verteilung der Umfangskrfte
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BAM, 142nd year (1997), Issue 2.
4. Summary