GERMAN TECHNOLOGY

German greatness
looks at some of the newest developments coming out of Germany, which includes advances in LHDs, longwall shearers and screens

ith the closure of many of Germanys mines over the last few decades, the manufacturers that were established on the back of this success have had to evolve. To do so, they have branched out from Germany and coal mining, into other major mining centres, equipped with new hard rock technologies. Research and Markets Metals and Mining: Germany Industry Guide report offers a background to Germanys metals and mining industry. It includes five-year forecasts for aluminium, coal, metals and mining and steel. Highlights of the report include: The German aluminium market generated total revenues of $1.3 billion in 2007, representing a compound annual growth rate (CAGR) of 6.7% for the period spanning 2003-2007 The German coal market generated total revenues of $13.1 billion in 2007, representing a CAGR of 6.9% for the period spanning 2003-2007 The German metals and mining industry generated total revenues of $57.6 billion in 2007, representing a CAGR of 7.8% for the period spanning 2003-2007 The German steel market grew by 20.6% in 2007 to reach a value of $34.4 billion. Beginning with all-important sampling for exploration and other tasks, Bruker AXS new simultaneous WDXRF spectrometer S8 LION combines ease-of-use with analytical speed and reliability for process and quality control. It is

designed and built for speed and accuracy and can simultaneously measure up to 16 elements with a precision of 0.05% (RSD) and time-toresult of less than 60 seconds in raw materials and industrial minerals. In designing the spectrometer, applicable industry standards such as ASTM C-114, were matched or exceeded. The company says the S8 LION is one of the most compact high-performance simultaneous WDXRF spectrometers in the market, allowing simple integration into any laboratory and process automation. It integrates Brukers unique TouchControl and SampleCare features for extreme ease of use and reliability. TouchControl enables simple and essentially fail-safe operation via the integrated touch screen, requiring virtually no user training. Several languages for the user interface are available, such as English, Spanish, Chinese, Russian and Portuguese. SampleCare ensures maximum uptime and availability with a tubeabove-sample setup protecting the S8 LION against contamination. The ease of use with TouchControl and SampleCare technology, as well as the new, unique free-lime channel, which integrates XRD capabilities into the XRF spectrometer, makes the S8 LION an ideal tool for precise, rapid and effective process and quality control.

ThyssenKrupps solution for the Cllolar coal mine included a Truck Dump Station that can be fed by five trucks simultaneously. Each station has two feed hoppers and type DRS 950 x 2500 CS sizers underneath that are fed directly by the dump trucks

Going underground
Germany has some big manufacturers for underground machinery and one such is Paus,

which since its foundation around 40 years ago has been focused on the transport of explosives, especially ANFO. It also, of course, makes LHDs, trucks and a wide range of utility vehicles. The Paus Universa 50 carrier vehicle allows the transport of up to 1.5 m3 of explosives. By means of the hose pusher and a dosing unit, especially developed for filling blastholes, explosives can be placed in the holes in a suitable and cost-effective way. The telescopic working platform allows access to heights up to 12 m. At the same time, the vehicle carries all tools and necessary blasting accessories, such as ignition systems and cartridges. The Universa 50 platform is available for payloads from 4.5 to around 7 t. This machine has, according to the company, proven its reliability for years and consequently gained a great reputation; the vehicle is equipped with articulated steering and four-wheel drive and is the basis for all possible underground transport jobs. In LHDs, GHHs new drive concept, the Efficient Drive System (EDS), has made a significant impact on its newest machine: the LF-10/11. The reduced dimensions, energy efficiency, higher productivity and

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GERMAN TECHNOLOGY
The reduced exhaust, noise and heat emissions of GHHs LF-10/11 lead to a significant improvement of working conditions in the workplace

ergonomically designed work space is, according to the company, only possible due to the introduction of EDS. This uses hydro-mechanic drives to alter pumps and motors, enabling LHDs to advance when loading, whilst the flow is set back to virtually zero. The drive and brake force is supplied to all four wheels during loading, tramming and braking, therefore the drive energy is split to mechanically connected axles. Using an intelligent combination of a contemporary diesel engine, hydrostatic power transmission and mechanical drive concept, fuel savings, driver comfort and reduced exhaust emissions are all achieved in underground operations to a level not previously experienced. Automatic transmission and a push button reverse gear aid the handling and speed of the LHD. After automatic hydrostatic deceleration, the LF-10/11 will be accelerated in the opposite direction without the use of a friction brake. For safety regulations, there is a service brake, but it is not in use under operating conditions. The maximum possible speed is adjusted automatically for incline or declines, with a reduction in pedal pressure causing automatic deceleration through the drive system. EDS reduces energy costs significantly through the optimisation of drives, engine rpm, pump and hydro-motor regulation for any mode of use, minimising the dissipation loss of the drive system. This results in a reduction in fuel consumption of 15-20%, depending on operating conditions, which in turn lowers exhaust emissions. Unlike conventional drive systems, low engine rpms are sufficient to keep the thrust or penetration. Schopf has been developing and producing robust LHDs for over 40 years. Its loaders are offered with both air- or water-cooled diesel

engines, and work efficiently in narrow working spaces, with bucket capacities ranging from 2.7 m to 6.0 m. Due to the companys centre oscillation technology, the front and the rear sections of the vehicles are equipped with two identical axles. Therefore the complicated oscillating axle design of the rear axle is unnecessary. This allows easy access to the engine compartment as well as making the rear vehicle section torsion free. Additionally, gearbox and transmission can be used in one module and do not need to be separated. The drivers seat is arranged crosswise to the driving direction in contrast to many other loaders which increases the drivers overall visibility, enabling him to easily drive backwards for the unloading process. This also aids manoeuvrability. The LHDs come with open or closed cabs, with air conditioning and comply with the ROPS/FOPS requirements.

The SFL 65 has hydraulic orbitrol control, heavy duty axles with POSISTOP and a Clark gearbox with integrated torque converter. This LHD can be equipped either with a Deutz BF6M013 or the TCD 2013 engine which both comply with the latest environmental standards. It has a standard bucket size of 2.7 to 3.5 m and can also be equipped with a 2.9 m side-tipping- or a 2.9 m ejector bucket. The ejector bucket can load into dumpers with a box height of up to 2,400 mm with the use of a special boom extension. With the side tipping bucket, transport vehicles or skips placed parallel to the LHD can be loaded directly, without changing the driving direction as the bucket hydraulically unloads across the centre line. The SFL 65 is useful in narrow tunnels, with a width of only 2,200 mm making it an efficient loading and transport vehicle for underground operations. Another is the SFL 100, which has a width of 2,500 mm and a bucket capacity of up to 6.0 m. It is equipped with proven components and a 200 kW water-cooled Deutz diesel engine. The loader has a payload of up to 12,000 kg and can be used in tunnels with a cross section of up to 4 m due to its easy manoeuvrability and compact design. Bucyrus is one of few companies with great expertise in longwall shearers. Since moving the shearer product to the Lunen manufacturing facility in Germany, it has invested extensively in the development of the next generation of Electra longwall shearers; with the first to roll off the production line next year. Building on

Schopfs SF L65 has hydraulic orbitrol control, heavy duty axles with POSISTOP and a Clark gearbox with integrated torque converter

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the success of those currently operating, the first next generation shearer will be an updated version of the successful Bucyrus EL3000. In Australia, a market where Bucyrus shearers have been very successful, over 500 Mt of coal has been produced with Electra shearers since the first machine was delivered in 1992. In 2008, four out of the top five producing longwalls used Bucyrus EL3000 shearers. In the US, Electra shearers are employed at some of the most successful installations and, in particular, at some of the most arduous operations in the market. The EL3000 shearers will incorporate many improved design concepts while retaining proven aspects such as the rugged mainframe for protection of the shearers major units, in particular the electrical compartments. The drive to ever increasing cutting heights is also addressed, with the ability to cut in excess of 7.0 m in the high seam configuration of the shearer. Once again, the flexibility afforded by the mainframe configuration allows it to achieve a wide range of cutting heights while using the same fundamental components of the shearer. The shearer also benefits from the newly developed control system, which brings the shearer control in direct communication with the well established PMC family of products. This provides a reliable and flexible longwall system automation network. Signal Peak Energy, Round Up, Montana, is developing and installing equipment to begin production from a new longwall mine in the Powder River Basin. The mine will produce at least 13 Mt of steam coal with the help of Becker SMC - the American subsidiary of the Becker Group - which provided a turnkey installation that includes a 100 kV/40 mVA substation with relay and control, switchgear, section/belt power distribution centres, and longwall power equipment. This will standardise the mine on Becker SMC equipment.

Bochum-based Eickhoff has always been a worldclass supplier of gearing for all aspects of the mining industry, including longwall shearers. Designed at its US facility, the LISA shearer electrical control system features a modularised layout and design that greatly reduces the number of wires, plugs and connections. This new control system for Eickhoff shearers is now in operation at an underground coal mine in southwest Pennsylvania. So far, results have been encouraging. The various display screens provide information on all parameters necessary to operate and maintain the machine including motor currents, winding temperatures, and oil pressures. In the event of trouble, the on-screen diagnostics will quickly lead maintenance personnel to the source of the problem. An on-screen fault message provides troubleshooting tips, location of test points (by compartment) and a part number of the component in the event that it would need to be replaced. A typical fault message is shown in the above diagram.

Processing and separation

Two separation companies have recently joined together to offer a complete product range of separation technology; including sensor controlled separation and the magnet technology for metals and minerals separation. RTT Systemtechnik in Zittau and Steinert Elektromagnetbau in Cologne will form RTT Steinert. This will bring together RTTs years of experience in the development and marketing of near infrared technology and Steinerts years of experience in the area of sensor sorting and magnetic separation. Steinert will be leading the worldwide aspects of the new company. We have created the unique opportunity worldwide to offer a comprehensive product range for the mining industry, as well as metal processing and domestic waste from one source, Franz Heiringhoff, CEO from Steinert, pointed out. The global sales presence as well as the possibilities of Steinerts worldwide service were a relevant argument to look for a closer cooperation with Steinert, emphasised Bert Handschick, CEO of RTT. Moving to a company expanding overseas, allmineral, the Duisberg based provider of dry and wet processing equipment, with such products as its alljigs, allflux and allair, in June, set up an Indian subsidiary, allmineral Asia, in a joint venture with Jyotirmoyee International. The company is now responsible for the marketing, supply, project management and service for all of allminerals mineral beneficiation solutions in India and Southeast Asia. allminerals Executive Director and allmineral Asias new Chairman, Heribert Breuer

The next generation of Bucyrus Electra shearers will support and advance current state-based automation technology. Its advanced control network allows the integration of all new developments - such as coal interface detection and radar

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comments, We will meet the everincreasing demand of our customers in Asia by enhancing our strong presence and raising the level of service and quality even higher. By having our own office in India, we are taking steps to expand our already very successful involvement in Asia. This is made possible by the fact that allmineral Asia has kept on the excellently trained and experienced personnel of Hari Machines mineral beneficiation branch, Sabayaschi Mishra, Head of allmineral Asia explains. Hari Machines remains the manufacturer of our equipments. The two companies allmineral and Hari Machines have been collaborating for a number of years already. The partners supplied iron ore processing equipment to Jindal Steel & Power for its 9.97 Mt/y plant, as well as to Brahmani River Pellets for its 3.62 Mt/y processing plant in Orissa, which will process previously unusable raw materials for pellet production with the help of this machinery. In total, the partnership has carried out 30 iron and coal processing projects across India since 2005. Cyanide effluent is a major worry to many mining companies. CyPlus has developed several processes for cyanide effluent treatment (CET), which are suitable for use in cyanideare impractical, as prohibitively high reagent consumption causes product decomposition. After collaborating in the field of CET with Inco Tech Canada for many years, CyPlus developed the CombinOx process and then acquired the knowhow for designing and operating the SO2/AIR process. CyPlus has succeeded in commissioning two CET Cold Caro's Acid systems for USA-based Jaguar Mining at its Turmalina and Paciencia gold-mining operations in Brazil. Cold Caro's Acid is a powerful oxidant that is produced in-situ by adding hydrogen peroxide to concentrated sulphuric acid. It is used in gold extraction to convert cyanide into cyanate. The CyPlus system is a proven process that achieves a yield of more than 80% of Cold Caros Acid, says Stephen Gos, Manager of Technology Solutions at CyPlus in Hanau-Wolfgang. The advantage of the CyPlus system is that the heat from the reaction can be controlled and kept at low levels, thus ensuring safe operation. A feasibility study conducted at CyPlus laboratories shows that the Cold Caro's Acid process outperforms other effluent-treatment systems. Basing its decision on the study and

CyPlus has commissioned two CET Cold Caro's Acid systems for Jaguar Mining at its Turmalina and Paciencia gold-mining operations in Brazil containing ore pulps. These have been developed as conventional methods, like H2O2,

EFFICIENT

DRIVE

SYSTEM

www.ghh-fahrzeuge.de

GHH Fahrzeuge GmbH Partner for underground mining solutions RELIABLE. PRODUCTIVE. PROVEN. The new LF-10/11 with EDS concept. For highest break out force and lowest operating costs in its class. EDS The new drive line concept for underground. Emscherstr. 53, D-45891 Gelsenkirchen, Germany Tel: +49 (0)209-389 07-0 . Fax: +49 (0)209-389 07-109

38 International Mining DECEMBER 2009

GERMAN TECHNOLOGY
the basic engineering package, Jaguar chose to install the system. Besides keeping cyanide levels in check, it is highly efficient as regards hydrogen peroxide and sulphuric acid consumption. We require low cyanide discharge levels for our operations and it is essential to perform this economically. With the CyPlus Cold Caro's Acid systems, we expect to reduce reagent consumption by more than 30%, achieving the same low cyanide levels of 10 ppm or better. The results from the commissioning phase indicate that we made the right choice, says Mauro Salim, Project Manager for both of the Jaguar Mining operations. Endress+Hauser supplies industrial measurement and automation equipment. It offers comprehensive process solutions for flow, level, pressure, analysis, temperature, recording and digital communications; optimising processes in regards to economic efficiency, safety and environmental protection. Application examples include: Flow Prowirl vortex flow meters measuring air injection for agitation in flotation cells Metering of sulphuric acid with Promass coriolis mass flow Metering of abrasive slurries Analysis of process and environment In slurries to control acid or lime milk addition with CPS pH sensors Turbidity and sludge level measurement in thickeners Acid concentration measurement in slurries using CLS conductivity sensors and Liquisys M transmitter Dissolved oxygen monitoring of effluent to rivers and ground using Liquisys M transmitters and COS sensors Levels Coal in bunkers or at flotation cells with Prosonic ultrasonics Long range ore pass levels with Micropilot M solids radar Sulphuric acid tank levels with Micropilot M radar Level and slurry density in autoclaves and flash tank levels with Gammapilot M radiometric sensors Pressure Hydraulic and conveying pressure in pipes and pneumatic loading lines for powders with Cerabar M ceramic cell version Differential air pressure control across the grinding mill with Deltabar S Temperature In slurry thickening tanks with tough Omnigrad TAF and TC sensors. Going up in scale, Engineering Dobersek, a plant engineering company out of Mnchengladbach has delivered two new Conticlass System plants to Ural Mining and Metallurgical Co (UMMC) in Russias Ural region. These plants are to increase the quantity and throughput of copper- and zincconcentrates in the companys mill. This system gives continuous classification of ores by constant pressure at the hydrocyclone inlet, as well as high density in the cyclone overflow. In addition, Dobersek says that approved pumps achieve ten times the life of conventional systems, by using a rotation speed control of the applied rotary pumps, pressure fluctuations are avoided and cost-intensive downtimes are minimal. In October, the company also received an order for a coal treatment and loading plant in Kakanj in Bosnia Herzegovina. The projects objective is to reduce pollution and transport costs which are caused by full-time trucking. The commissioning of the modern coal treatment and train loading plant is planned for early 2011.

Bulk handling
Haver & Boecker, a manufacturer of screening equipment, has reworked its series of freeswinging screens in the Haver Screening

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Group (HSG). These machines now benefit from proven and tested components being combined to create reliable and field tested specialty machines. Some of the other developments include a drive that enables amplitude-speed combinations in a wider range of 210 mm. This design accommodates new working conditions as well as a reduction in sound emissions. The company has also devised a new wear protection system that effectively protects the machine, which can be retrofitted to existing systems. This ensures that when worn components need replacing, there is minimal downtime. The screen frame of the HSG machines is engineered in a traverse design. The deck is clamped onto the frame with a patented retaining bracket instead of having welded seams. This supports the system, as well as allowing the brackets to take up several positions. In addition, the screen frame components, such as feed and transfer plates, are engineered to accommodate load bearing. The deck structure of its NIAGARA T-CLASS has been adapted to fit all conventional screening surface systems in the HSG range. These are essentially: Side-tensioned wire mesh, polyurethane or rubber panels Screwed-on or clamped perforated plates Clamped harp or special designs Screen modules made of polyurethane (PU) or rubber Modular frame with other screening media (e.g. PU base frame with harp wires). The machines are designed with the help of the NIAproject design software. This has a calculation model that is used to analyse the separation of the materials and then estimate the available screening area. This helps to select the right machine and parameters for the application. There is a growing acceptance of high pressure grinding rolls (HPGR) in the minerals industry. KHD Humboldt Wedag, a manufacturer of HPGR technology, introduced its Roller Press in 1984 to the cement industry. Beyond the high unit throughput, the low specific energy input and the reliable and efficient operation, further benefits of HPGR in minerals processing include: Fine crushing through partial recirculation Significantly enhanced metal recovery Improved downstream processing. In October 2009, Shandong Gold Group in partial product recirculation without the need for screening. Another HPGR circuit in gold ore is presently being commissioned by KHD at the Vasilkovka gold deposit in Kazakhstan with two RP 16-170/180s operating in parallel in closed circuit with partial product recirculation. The machines are designed for a throughput of 1,440 t/h. The RPs are installed as the tertiary crushing stage, before fine grinding and gold extraction. The high reduction ratio and the low energy input achieved through the use of HPGR units has provided a promising basis for further applications in copper ore processing in Kazakhstan. One of KHDs successes in HPGR installations is Compania Minera Huascos installations at Los Colorados iron ore deposit in the
Haver & Boecker screen deck in combined screening surface configuration

China awarded Humboldt Wedag Germany, a subsidiary of KHD-Group, the contract for the supply of a Roller Press (RP) for tertiary crushing of gold ore. This will be the first application of HPGR technology in the gold industry in China. The new RP system will be installed as the tertiary crushing stage at the 8,000 t/d crushing and grinding plant of Sanshandao gold mine in Shandong Province. KHDs scope of supply comprises a RP, type RPS 7-140/110, equipped with its patented, wear resistant roller surface with stud-lining wear. The press with a throughput rate of up to 800 t/h will be operated in closed circuit with

Atacama region of northern Chile. The RP 16170/180, equipped with roller surfaces with stud-lining operates in closed circuit with vibrating screens. It has been in operation since November 1998, with a throughput of up to 2,000 t/h. Norbert Becker, Vice President for Process Solutions Mining, Siemens says that In terms
Norbert Becker, Vice President for Process Solutions Mining, Siemens says that Wherever energy savings, availability, reliability, reduced equipment wear and difficult terrain are an issue, gearless drive systems are the most economical drive option for large belt conveyors. Pictured here, the up hill conveyor gearless drive system for the Prosper Haniel underground mine in Germany

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Komatsu shovels are not just applied in extreme conditions. They are recognised around the globe as reliable, efficient machines. This is emphasised by the fact that the company is about to ship its 75th PC 8000

The stacker was successfully delivered three weeks ahead of schedule; the nominally 100 m wide stacker has twin booms and a capacity of 2,750 t/h. The stacker is rail mounted, travelling up to 165 m and will generate two 20 m high parallel coal stockpiles. This machine is a key component of the whole expansion plan for the coal terminal.

Open-pit technology
A Komatsu PC 8000 mining shovel built in Germany is being successfully operated at 4,000 m above sea level (asl) in a Chilean copper mine. This is the first super large hydraulic excavator of its class working in such altitude where it is digging rock and overburden. The machine is loading Komastu 930 E haul trucks with an overall payload of around 290-t in four passes. The PC 8000 is able to operate in this environment due to the special Komatsu shovel design and there are likely to be more shovels operating in the South American Andes as well as being involved in one of the worlds largest gold projects between the Chilean and Argentinean border at 5,200 m asl. From 2010, Komatsu Mining Germany will offer all shovels with Tier II emission certified diesel engines as an option. With the implementation of Tier II, all machines will be equipped with the Komatsu vehicle health monitoring system (VHMS) as standard, contributing to efficiency. The customer has

of energy efficiency and availability, gearless drive systems (GD) are a logical next step in the evolution of conveyors. Belt conveyors are increasingly being used in operations due to their efficient and cost-effective qualities; however Becker sees GD as a way to further improve efficiency. Becker: In the mid 1980s Siemens built the first and the last up hill conveyor GD system, for the underground mine Prosper Haniel in Germany. This is still in operation and has remained since day one, extremely efficient and very reliable. Subsequently, popularity for the GD solution for conveyors waned, due to various circumstances like capital cost and power requirements. Today however, interest has picked up again. In the past 30 years Siemens has continuously developed [its] GD systems and gained a lot of experience in low speed applications like mill drives, mine winders, bucket chain excavators and draglines. This know-how is also applicable for GD conveyors solutions. In general the GD solution is based on a low speed synchronous motor, fed either by a cyclo-converter, or by a voltage source converter dependent on line conditions and special drive features. As there is no gear between pulley and motor, and the motor has no bearings, the drives benefit from the following: No significant inrush current during conveyor start-up due to vector controlled drive No energy loss during start-up within the secondary resistor starter or fluid coupling No energy loss due to load sharing during operation. Becker explains that Compared to conventional conveyor drives, energy consumption can be reduced by up to 20%, depending on the specific conveyor application.

This is achieved by eliminating gears and load sharing resistors as well as matching the conveyor speed to the material flow. Slip starting can also be avoided completely. Tenova SEMF, part of Tenova TAKRAF, a leading supplier of mining and bulk handling technology, products and services, has recently obtained the Practical Completion Certificate for its QBH coal stacker installation located in Brisbane, Queensland. The long travelling twinboom coal stacker with tripper was designed and constructed for the Fisherman Islands storage facility expansion, part of the Queensland Bulk Handling (QBH) coal terminal, fully owned by New Hope Corp. Tenova SEMFs contract was for design, fabrication, mechanical fit-out, delivery, erection and commissioning, and formed part of QBHs wider stockyard upgrade, which is expected to be completed by late 2010.

Liebherrs new R 9250 E takes only three bucket loads to fill an 80-t dump truck, or four to five bucket loads for a 120-t dump truck

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the development of the R 9350 E being very influential. The R 9250 E provides a motor output of nominal 1,050 kW (nominal excavator power of 1,100 kW) at 6,000 V and 50 Hertz. The AC squirrel cage motor, with the long motor lifetimes, requires only minimal maintenance contributing to increased uptime and machine use. Furthermore, mines with access to low cost electricity can benefit from lower operating costs in comparison to diesel powered units. The electrical motor is started by a starting transformer. All electrical installations are protected on IP 55 EN 60529 Standard. The electrical compartments are sealed and secured to withstand tough mining applications. The standard electrical version of the excavator is equipped in backhoe configuration with a 9 m gooseneck boom and a 4-m stick. In face shovel configuration the machine is equipped with a 6.3 m swing boom and a 4.2 m shovel stick. Both have a nominal bucket capacity of 15 m; however this can be customised to suit material properties and mine site requirements. The first units have been delivered to Russia and have commenced operation. One of the countrys bigger manufacturers has been taking part in an interesting coal project in Turkey. Park Teknik, part of Ciner Group company, won the tender to operate

Wirtgens 4200 SM surface miner was premiered in March at the companys headquarters in Windhagen. For a full report on the machine see International Minings May issue, pp34-35

access to VHMS data and can be proactive with preventive maintenance and service. In 2009, Komatsu introduced a new comfortable operator cabin. The cabin has a spacious design with a base area of about 3.7 m. Major improvements are: increased allaround visibility, fully-fledged trainer seat and reduced maximum noise level of 76 dB.

Furthermore, the machine interface has changed slightly in order to provide a comfortable and productive environment for operators. With the launch of the mining excavator R 9250 at Bauma 2007 and the presentation of the first shovel version at MINExpo 2008, Liebherr is now making this successful model available with an electric drive unit. Partly significant fuel price increases and an increasing awareness of alternative energy sources have prompted the company to produce the electric version. Liebherr engineers drew upon many years of experience to produce the R 9250 with

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44 International Mining DECEMBER 2009

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the Cllolar coal mine in Turkey. This will fuel the Afsin Elbistan thermal power plant. The tight time frame of this operation necessitated a solution that ensures the timely coal supply of the power plant. After many discussions, ThyssenKrupp Frdertechnik, Business Unit Mining presented a solution for Cllolar involving a Truck Dump Station (TDS). This company won a contract for four stations to be fed with either overburden or coal. Requirements included: The height of the plant had to be as low as possible, to reduce costs for the retaining wall and the excavation of the pocket, while at the same time considering the material flow and providing steep walls for the hopper and the crusher discharge chute To fill the feed hopper with the existing truck fleet with a capacity of around 17 m/truck; no small task considering the required handling rate of 5,600 m/h To minimise backing and clogging of the sticky material To design a crusher unit that will prevent the downstream conveyor from being fed with oversized material Relocation of the TDS within the shortest possible time and at low costs To design a retaining wall that can be reused. The result was a TDS that can be fed by five trucks simultaneously. Each TDS has two feed hoppers and type DRS 950 x 2500 CS sizers underneath that are fed directly by the dump trucks. Hoppers and sizers are mounted on the same frame so that a transport crawler, also within the scope of the order, can relocate the entire unit. To minimise backing and clogging of sticky material, the hopper walls are steep and supplied with air canons and heating plates for winter operation. The sizer drive units are frequency controlled to regulate the material flow onto the overland conveyor. Maintenance platforms, which can be installed for service on the complete sizers, were also within the scope of the order. A curved beam with hoist is mounted above the sizers for minor maintenance work. The retaining wall is made of single concrete elements, with its size and weight allowing for transport by normal trucks. The client has decided to purchase an additional set to reduce preparation time for the new location. The MTU Series 1600 engine was released earlier this year. This diesel engine for the offhighway market, with power outputs between

RUD-Erlaus GARANT PROTRAC X18 for traction and safety

270 and 730 kW, expands the companys product portfolio in the lower power range. It is the smallest engine manufactured by MTU. It comes in an in-line configuration with six cylinders as well as in V-configurations with eight, ten and 12 cylinders, covering a displacement range from 10.5 to 21 litres. The 1600 complies with the current exhaust specifications of EPA Tier 2 (power output above 560 kW) and EPA Tier 3 (power output below 560 kW) without the necessity of exhaust after-treatment measures. Thanks to its modular design and standardised interfaces, it is open to future integration of exhaust after-treatment systems. RUD-Erlau notes that earthmover tyres require special attention. Without tyres,

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DECEMBER 2009 International Mining 45

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GERMAN TECHNOLOGY
The semi mobile crushing station at the Baiyinhua coal field in Inner Mongolia, like the one pictured here, consists of a complete primary crushing station based on the Sandvik centre sizer CR610 with a crushing capacity in excess of 2,200 t/h

loaders, trucks and graders are not much more than grounded, lumps of iron. And there is so much that can go wrong. Badly fitted or poorly inflated tyres can affect handling safety, destroy rims, over-heat, burst and raise fuel costs. No matter how well-made, unprotected tyres will wear too quickly and can be destroyed and, in some conditions, become costly scrap in an instant, the company says. Certain plant managers see tyre protection and traction chains as essential accessories to the extent that they are now a common sight, not only in Chile and South America but anywhere in the world where the working environment is tough on tyres. With 65% of the world market, it is most likely that the tyre protection chain (TPC) you see in action will be a RUDErlau patented design, the company claims. In Chlie, Antofagasta, Codelco, Escondida and other copper miners count amongst RUDErlaus many long-term customers. Wheel loaders dependant on RUD-Erlau TPCs, include CAT 992s, CAT 994s and LeTourneau 1400s and 1850s. The company reports that the close mesh of the FELS CROWN X22 RUD-Erlaus largest diameter forged link - provides complete protection from abrasion and suddendeath, sidewall piercing. There are CAT 824 and 834 wheel dozers fitted with RUD-Erlaus GARANT, GARANT 10 ROYAL X16 and GARANT 10 IMPERIAL X18. These 16 and 18 mm diameter links can be configured as tight or open mesh depending on whether ground conditions make traction or abrasion the most important considerations. Losing control of a haul truck with a 400 t payload is a frightening experience and maintaining traction and operating safety over the winter ice of the high Andes is of real concern. For safety, Komatsu 830 and 930 and CAT 797 haul trucks rely on traction chains such as RUD-Erlaus GARANT, GARANT 10 CROWN X22, GARANT 10 TERRAPLUS X 22, and PROTRAC X18. In 2009 alone, RUD-Erlau delivered and fitted over 50 sets of TERRA PLUS to Chile. Developed in response to Chiles mining conditions, TERRA PLUS, with its unique selfcleaning Z links and deep-biting studs, is RUDErlaus latest and most effective answer to beating snow, ice and soft-ground. RUD-Erlaus special duty TPCs include the FELS Toro X19 for all-round protection of low profile tyres used in underground duties.

After factoring in investment in the chains and a slight rise in fuel consumption, analysis shows that operations can expect at least 10% improvement in operating costs. The gains arise from reducing accidents and less damage to plant and injury to personnel, more than doubled tyre life and assured plant availability. With high quality protection, operators can save more dollars by using part-worn tyres. The links must be as light and as hard-wearing as possible and have consistently high-quality welding done by the most modern methods. Though headquartered in Sweden, Sandvik Mining and Construction has a big presence in Germany. Its production unit in Bergneustadt, uses the best of innovative technologies and expertise to provide comminution machines like the series of CR800 hybrids, CR600 sizers, CR400 roll crushers and CM400 hammer mills. The factory is situated in the district Nordrhein-Westfalen, in the very heart of the German iron and steel industry. The area possesses a long tradition of German machine engineering and manufacturing. In addition, worldclass technical universities in the region provide local companies with a continuous stream of highly educated engineers. The factory in Bergneustadt is such an example. Production started in 1947 under the name Aubema. Today it is an important part of Sandvik, and up to date more than 7,000 machines have been distributed to over 70 countries. It also manufactures fully-mobile, semi-mobile or fixed crushing stations and recently delivered a semi-mobile coal crushing station to the Baiyinhua coal mine in one of the largest coalfields in Inner Mongolia. At Port Warratah in Newcastle, Australia, the

worlds largest export coal terminal, as part of an expansion of the port, Sandvik was commissioned in 2007 with delivering three new giant bucketwheel reclaimers, the biggest for coal handling in Australia. These are currently being set up on site. There was also the matter of the old equipment, which is 26 years old, to be sorted out. This is where Sandviks Saarbrcken centre of competence for the new area of Global Technical Services Materials Handling stepped in. The deconstruction of two old stackers with an operating weight of 829 t each in the summer of 2009 and two old bucket wheel reclaimers, each weighing 1,782 t in the spring of 2010 was included in this contract. This is being co-ordinated between Sandvik Saarbrcken (technology) and Sandvik Perth (project execution). Following Wirth becoming a fully controlled subsidiary of Norwegian company Aker Solutions in early 2009, the German manufacturer has been incorporated into Aker Wirth. In June, Per Harld Kongelf, Executive Vice President of Aker Solutions said: Our acquisition of Wirth complements and expands our customer offering. Aker Solutions is now one of only two suppliers in the world of complete drilling packages. In addition, the acquisition of Wirths mining and construction expertise strengthens our presence in the process and construction markets. For more than 20 years Wirth has been successfully collaborating with Aker Solutions on drilling packages. By formalising this connection through acquisition, the goal is to strengthen the existing collaboration and expand it to all of Aker Solutions drilling activities globally. IM

46 International Mining DECEMBER 2009