News in brief 01_2015

Tunnelling operations, opencast mining and bulk materials processing, handling and storage are activities that frequently generate large amounts of dust.

High levels of dust make are also a problem in the waste recycling business. This has an adverse effect on people and on the environment and results in increased wear and tear on machinery and equipment. Those who have to work in dust-laden environments can suffer from heart and circulatory problems, shortness of breath and mucous membrane irritations. Plants growing in such areas will also be affected by deposits of fine dust that will limit or even prohibit natural functions such as photosynthesis. Dust deposits on machines and equipment leads to higher rates of wear and this results in an increased need for maintenance and repair work. Dust is not only bad for the environment and harmful to human health but can also prove extremely life-threatening when a dust explosion occurs. Such events can be effectively counteracted using water sprays. terz GmbH, which is based at Kirchberg/Hunsrück, manufactures the Nebolex atomisation system that uses water-spray technology for dust suppression.

Effective dust binding is based on the principle that dust particles have an affinity for attaching themselves to fine water droplets. This attraction can be used to bind the dust that is generated during material processing and conveying operations. However this can only happen if the water is provided in a form with a sufficiently large surface area. The NEBOLEX system features self-aspirating atomiser heads that break the water down into fine droplets.

The system, which is modular in design and can easily be expanded if required, essentially comprises the following modules: a compressor for creating compressed air, a control and regulating unit and a patented atomiser rail with integrated spray heads.

The control unit allows different sections to be activated as and when required. This is particularly useful when the system is fitted to larger installations where all the different operating components, such as belts and feed hoppers, do not have to be in operation continuously at the same time.  All relevant parameters, including material quantities and outside temperature (risk of freezing), are monitored and factored into the operation of the system. Control is by PLC, relays or manual switching.

The atomiser rails can either deliver the water sprays directly on to the material or can be used to create a horizontal or vertical spray curtain. Large pipe cross-sections are used so as to prevent line blockages. This means that the system can run on surface water or cistern water, which only has to be screened prior to use.

Belt transfer points constitute a particular problem area where the dust generating material has to be permeated and the dust fraction humidified. The aim here is to bind the dust as much as possible before it is generated, thereby preventing dust swirls from being created. To achieve this effect the atomiser rails are mounted in such a way that the spray jets are entrained at an angle of about 30° to the downward flow of material.

Where it is not possible to introduce moisture directly into the material the solution is to create a horizontal or vertical curtain of spray. This means that the volatile dust picks up moisture as it passes through the spray barrier and falls to the ground due to its increased weight. This type of system is especially suitable for feeding hoppers, lorry charging points and loading/unloading stations.

If the systems are switched on and off by remote control they can be set to operate for a predefined period or the sprays can be deactivated manually if required. The huge magnification of the water surface results in a water infiltration rate of 1 – 5 ‰, depending on the material being treated. Both types of suppression system can be combined for optimum impact.

If requested, the installations can be fitted with a diagnostic function containing a communication processor and USB link. This means that a record can be kept of function tests on the spray-mist generation at the atomiser heads and leakage tests on the different water supply lines and this information can be transferred to a computer for storage. The diagnostic routine is carried out automatically in conjunction with a PLC system. The diagnostic intervals can be freely selected and adjusted to suit the prevailing conditions. (Terz/Si)

Further information:
Nebolex Umwelttechnik – Terz GmbH

Voith recently manufactured their 1,000th fluid coupling type TPKL. This coupling will go to the DaTong Coal Mining Group in China. The group has already made good experiences with Voith fluid couplings: Convinced by the good performance of hydrodynamic power transmission the decision for the drive line arrangement in the main belt conveyor of a new coal mine was also made in favor of Voith fluid couplings. In this specific case the mine will receive four fluid couplings type TPKL. The fill-controlled fluid couplings will be used in a 6.4 MW belt conveyor drive with demanding requirements. The 3,160 m (10,367 feet) long underground belt conveyor is driven by four 1,600 kW motors, with a planned capacity of 4,000 t per hour. The belt conveyor is designed for a demanding workload as it will transport coal uphill at a 14° angle.

Voith started the production of the TPKL coupling series in 1997. This fluid coupling type was especially developed for demanding belt conveyor applications in mining. The coupling type provides a torque limitation for a smooth start-up of the belt conveyor. It allows active load sharing with multi-motor drives. Thanks to its standstill cooling function it can handle difficult start-ups multiple times in succession. (Voith/Si)

Further information:
Voith Turbo GmbH & Co. KG

Purchased ‘as seen’ or refurbished – we provide for both options RAG Mining Solutions has expanded its product range and in addition to field-tested machinery is with immediate effect in a position to supply refurbished equipment and complete systems for underground use.

Refurbished machines are available in three categories to suit customer requirements: repaired and cleaned up, ready to run or fully refurbished. The offer is aimed at customers who are seeking to procure underground equipment for winning, roadheading and support operations, ventilation and air conditioning, automation and logistics.

RAG Mining Solutions can now also provide complete systems in full working order for both coal plough and shearer faces. Entire systems are also available for mechanised drivages with roadheading machines and for conventional shotfired drivages with drill jumbos, loaders and support setting platforms.

The machines and equipment supplied by RAG Mining Solutions are in strong demand on the world market, for as well as providing the relevant hardware RAG Mining Solutions also has the expertise required to ensure that it is set up and operated in the proper manner. And this represents a cost-effective way to further improve productivity and safety in the international mining industry.

Further information:
RAG Mining Solutions

The development of cleaner, safer and more efficient manufacturing, construction and mining equipment will be enhanced thanks to research, development and innovation at Atlas Copco, supported with financing from the European Investment Bank (EIB). Under an agreement signed in Luxembourg, the EIB will provide a EUR 300 million loan to Atlas Copco, one of the world leaders in compressors, construction and mining equipment, power tools and assembly systems. As part of Atlas Copco’s long-term funding programme, the loan will support the development of more efficient, more environmentally friendly and safer products. The company’s activities in research, development and innovation, mainly based in Sweden and Belgium, also involve close cooperation with European universities and research institutes, helping to disseminate cutting-edge technologies.

Jonathan Taylor, EIB Vice-President with responsibility for lending in Sweden, stated: “We are glad to sign this agreement with Atlas Copco, a global leader in the technology of compression, mining and rock excavation. This will support innovation in a key area of the economy, reduce carbon emissions, improve energy efficiency, and enhance the safety of workers”.

The project supported by the bank of the European Union will be carried out from 2015 until 2018 and implemented by more than 5,000 Atlas Copco employees, with some 1,350 directly involved in the research and development work. EIB Vice-President Jonathan Taylor commented: “Projects such as this strengthen the competitiveness of European companies, so enhancing Europe’s position as a major technology supplier and supporting skilled employment opportunities.”

Further information:
European Investment Bank EIB 

Sandvik Mining has expanded its CH800 series of mining cone crushers, launching two technologically advanced models that improve productivity and profitability in the mid-range segment. Sandvik CH860 for high-capacity secondary crushing and Sandvik CH865 for high-reduction tertiary and pebble applications feature higher crushing forces relative to mantle diameter and a 500kW motor. The new crushers combine a range of advanced automation features for a more secure and productive process.

Product line manager for cone crushers at Sandvik Mining Andreas Christoffersson said: “We scaled down our larger Sandvik CH890 and Sandvik CH895 mining cone crushers to create two mid-range models that are even more productive, robust and reliable, and feature enhanced environmental, health and safety characteristics.

Depending on the application Sandvik CH860 and Sandvik CH865 outperform competing equipment in the mid-range segment by as much as 30 % and deliver a two-fold increase in performance range.”

The systems in Sandvik CH860 and Sandvik CH865 enable real-time performance optimisation, while smart, compact design solutions reduce dynamic loads and minimise engineering and installation work. The crushers feature fewer moving parts than competing models, according to Christoffersson. Non-welded, bolted liners on the top and bottom shell enable safer, easier maintenance. Both new crushers also feature the company‘s automatic setting regulation control system (ASRi) and hydroset, to ensure automatic operation at peak performance around the clock. ASRi constantly monitors pressure, power draw and mainshaft position, and automatically adjusts the setting during full load. The hydroset main shaft support system provides protection from overloads by permitting tramp iron and other uncrushables to pass through the crusher before automatically returning to the original setting. The system automatically compensates for crushing chamber wear to provide consistent product size.

“Hydroset enables us to incorporate our unique PLC-controlled electric dump valve for tramp iron protection, which significantly reduces pressure peaks and mechanical stress on the crusher, greatly improving reliability,” Christoffersson added.

Close to one year of rigorous testing in a Chinese iron ore mine has produced excellent results. “In these challenging times mines are often looking for increased productivity without necessarily expanding their plant,” Christoffersson said. “Sandvik CH860 and Sandvik CH865 are easy to install as replacements to achieve this. In the test site we replaced a similar sized crusher, on the same foundation, to greatly increase final product and significantly extend crushing chamber liner life. The electric dump valve repeatedly proved its tramp iron protection value, reducing costly unplanned breakdowns.”

Further Information:

Sandvik Mining and Construction
Central Europe GmbH
www.sandvik.com
www.mining.sandvik.com

On 18 and 19 June 2015 the Kongress Palais in Kassel will play host to the 13th Mining Forum and more than 300 key decision makers, experts and specialists from the mining and raw materials industries are expected to be there. This year’s Forum will also target an international audience for the first time.

Coal, salt and mineral ore: with another list of top-class speakers already lined up, the 13th Mining Forum will once again be providing a practical insight into developments in the mining and raw materials sectors. A cleverly-chosen mix of conventional and future-oriented themes will ensure that delegates get an all-round perspective of what is going on in the mining and extractive industries. It is another opportunity for the Forum to consolidate its reputation as a top-flight reference symposium and unique platform for information exchange at expert level.

According to Jens-Peter Lux, DMT Business Unit Manager for Geo-Engineering, giving the Mining Forum an international focus for the first time will ‘set the bar even higher and boost the exclusive nature of the event.’ This year’s Forum will have as its exclusive partner Kassel-based K+S Aktiengesellschaft, one of the world’s leading providers of potash and magnesium products.

Trade exhibition provides the centrepiece

The attached trade exhibition creates the perfect centrepiece and meeting-point for speakers and visitors alike. The 400 square metres of show space provides exhibitors and sponsors with an unrestricted networking environment where they can present their business activities to potential customers in a focused way. As well as arranging a special presentation area DMT is able to offer high-profile , communicative service packages for exclusive company presentations both during and after the Forum – so brand presence is well catered for.

For an update on the programme and other information relating to the 13th Mining Forum visit www.the-miningforum.com.

Sponsors and exhibitors can telephone Carolyn Tepel directly on
+49 (0) 201/172-1814 or email to
carolyn.tepel@dmt-group.com.

Further information:
DMT GmbH & Co. KG

In January 2015 after proper preparation, the network mining has been established. In time for the conditional breakaway of the domestic coal market as customers in 2018 and taking into account the increasingly difficult prospects for opencast lignite mines, in agreement with the North Rhine-Westphalian Ministry of Economic Affairs, appropriate measures have to be taken. By co-working with partners such as NRW International, VDMA Mining and other stakeholders the supply industry is assisted in the development of foreign markets and alternative business fields. An outlook for revenue stabilization of predominantly SMEs companies is pointed out in order to support the preservation of jobs in NRW. The Network Mining and Energy will act as a neutral moderator and will be in direct professional exchange with the companies and support their business models and feasibilities. The companies shall be accompanied on the markets successfully and practically.

Since January 1st 2015, Dr.-Ing. Eckehard Büscher heads the Network Mining and Energy under the supervision of Energie-Agentur.NRW in Dusseldorf. As director of the International Coordinating Office of the German geothermal industry at GZB (International Geothermal Centre, Bochum), he has experience with the development of international networks. Previously, he worked as Managing Director (public utilities, strategic consulting firm) and with an international utility company. Dr. Büscher is a Mediator (CCI,) lectures as an assistant professor at the University of Bochum and is accredited as an expert of the energy sector in the EU-Commission.

The mining sector within the network mining is managed, also since January 1st, by Peter von Hartlieb. Since the early 1970ies he is conducting business in global mining for German companies and organizations and represents extensive experience with North- and South America, China, Russia and other target markets. As part of the obligations the NRW working group mine gas, which exists since many years under the technical direction of Prof. Dr.-Ing. Axel Preusse, Rheinisch-Westfälische Technische Hochschule (RWTH) Aachen, is integrated into this area.

“SMART MINING: Think big, aim high, work smart”. This is the idea of the new network MINING of the EnergieAgentur.NRW and the title of the kick-off event. The event will be held on March 24th at CASINO Zoll-verein World Heritage Zollverein in Essen in the presence of NRW Minister of Economics Garrelt Duin.

Attendees will include companies from the open pit and underground mining, representatives of the Ministries in Düsseldorf and Berlin, the mining authority, RAG Aktiengesellschaft, associations, unions and banks. Short presentations provide ideas and insights on current and future orientations of the industry. A special highlight of the afternoon promises to be the panel discussion where the export opportunities in the industry are discussed.

The free registration is possible at
www.energieagentur.nrw.de/bergbau. Please contact Ms. Inken Kienzle, public relations and communication in the network Mines, for any further questions under kienzle@energieagentur.nrw.de.

In cooperation with the Ministry of Economy of Saskatchewan the Competence Centre for Mining & Mineral Resources within the Canadian German Chamber is organizing a German delegation to the 7th Annual Saskatchewan Mining Supply Chain Forum in Saskatoon which will take place from April 13 – 16, 2015 in Saskatoon. Participants will get to know procurement departments from various mining companies, visit a mine and meet with most significant stakeholders in Saskatchewan. Target group for the delegation are mining equipment suppliers, consultants and associations.

The Annual Saskatchewan Mining Supply Chain Forum is hosted by the Saskatche-wan Mining Association and the Saskatchewan Ministry of the Economy. It provides detailed and practical information on how manufacturers, construction, equipment and service providers can access mining supply opportunities. The forum topics include: overview of operations and projects by Saskatchewan mining companies, information on opportunities to supply equipment and services to the mining industry, process and steps to become a supplier to the mining industry.

After the event, the Competence Centre will meet with selected EPC companies in Saskatoon to gain further insight into the requirements to successfully conduct business within the mining supply chain (mainly Potash, Oil & Gas and Uranium).

The organisation and supervision is free of cost. Attendees are responsible for travel, hotel and event registrations cost.

For further information and registration:
Deutsch-Kanadische Industrie- und Handelskammer

Open pit mining and underground solutions provider, Tenova TAKRAF, has completed the supply and installation of a complete Bucket Wheel Excavator (BWE) system for Zhahanaoer Open Pit Mine in Inner Mongolia, China. The system, which features the largest Bucket Wheel Excavator-Conveyor-Spreader-combination of its kind in Asia, was inaugurated in late November 2014, attended by representatives of the client, CPI Mongdong Energy Group. The inauguration followed successful performance testing, which confirmed the efficiency and reliability of the entire system and exceeded the expectations of all parties.

The system consists of a large-scale Bucket Wheel Excavator SRs 2000 (rated capacity 6,600 m³/h) with loading unit, a 7,750 m long conveyor system consisting of five flights as well as a compact spreader with tripper car on rails. The Bucket Wheel Excavator reaches 30 m digging height, and although it has a service weight of about 3,300 t, it has a ground pressure much lower than that of a D11 Dozer. In order to properly handle peak capacities the conveyor system as well as the spreader have a design capacity of 7,900 m³/h. Those conveyors running along the excavator bench and along the waste dump are shiftable.

The project commenced in September 2009 with the Bucket Wheel Excavator, spreader and conveyor system awarded in three stages from 2009 to 2011. The complete turnkey project covered design, supply, transportation, on-site installation, commissioning and testing.

The project site is located approximately 700 km from Beijing in remote northern China, where the extreme climatic conditions see winter temperatures of down to -40 °C and summer temperatures of up to +40 °C.  Despite the highly challenging conditions, the project teams achieved a smooth erection and commissioning process, completing the project on schedule in early November 2014.

The project is regarded as an important milestone in the development of China’s mining industry, typified by a trend towards larger scale mines and mining equipment. It also provides a good example of successful German-Chinese-cooperation. For Tenova TAKRAF, the project continues its success with the supply of Bucket Wheel Excavators to China, and follows the delivery of two BWE systems to Yuanbaoshan in the 1990s.

Further Information:
TAKRAF GmbH

Environment-friendly community heating from the nearby STEAG New Energies biomass-fuelled thermal power station, which has already been supplying heat to the Mügeln district of Heidenau, is to be extended to include Heidenau South and the existing circuit is being enlarged for this purpose. By the end of 2015 some 4,500 households will be connected into the supply system. The project will further strengthen the long-standing supply partnership that has existed between Heidenau Technical Services and STEAG New Energies GmbH.
Construction work commenced in November 2014. The new heating pipeline is to run for nearly 3 km through the town of Heidenau and heat is scheduled to be delivered through the new line in time for the heating season commencing in autumn 2015. According to Dr Stephan Nahrath, chairman of the management board of STEAG New Energies GmbH, the heat will be generated at the company‘s biomass-fired thermal power plant in Dresden and then fed into the extended district heating network. The new thermal pipeline, which is expected to provide a CO2 saving of 1,500 tonnes a year, will increase the existing supply output by 7 MWth.
The more eco-friendly the energy, the lower is the primary energy factor, i.e. the ratio between primary energy and final energy. In the case of the Heidenau supply system the primary energy factor is zero. And this benefits contractors and developers who are undertaking new-builds or energy upgrades to existing buildings. (STEAG New Energies GmbH/Si)