Sandvik AB

Sandvik continues to be a leader in mining automation with the introduction of the mining industry’s first interoperability platform for autonomous underground loaders and trucks: The AutoMine® Access API. Delivering on the promise made earlier this year at Goldcorp’s #DisruptMining event, the AutoMine^® Access API specification is now available and is the next step in Sandvik’s continued journey to set the industry standard for mine automation and digitalization.

The AutoMine^® Access API gives mines the power to connect non-Sandvik equipment to AutoMine^® – moving underground mining digitalization even further.

“As a world leader in underground automation, we have a responsibility to make this game-changing technology easier to implement for the mining industry,” said Patrick Murphy, President Rock Drills & Technologies, Sandvik Mining and Rock Technology. “While we think customers will achieve the highest performance with Sandvik equipment, we recognize the need to unlock automation’s full potential for all equipment regardless of manufacturer. Customers with mixed fleets will now have the full power of AutoMine^® behind them.”

How it Works
The AutoMine^® Access API is a standard set of pre-defined interfaces for connecting third-party loaders and trucks to AutoMine^®. This means a mixed fleet of underground loaders and trucks can now be managed and controlled with one seamless system.

An API (Application Programming Interface) is a set of functions and procedures that allows the creation of applications that access the features or data of an operating system, application, or other service.

The third-party equipment is also required to meet the AutoMine^® safety standards.

Driving a Digital Ecosystem
The AutoMine^® Access API is another step in Sandvik’s journey to drive a digital ecosystem that makes mining smarter, safer and more productive.

In 2018, Sandvik Mining and Rock Technology released its Interoperability Policy outlining the how Sandvik systems can communicate within a digital ecosystem including data accessibility, fleet data compatibility, data rights and control, and data privacy.

The momentum continued in 2019 with the acquisition of Newtrax, a leader in wireless IoT connectivity for underground hard rock mining, and the announcement that My Sandvik, Sandvik’s telemetry solution for machine health and productivity data, would also be available for non-Sandvik equipment.

“Sandvik has been leading the market in underground digitalization for years, with thousands of pieces of equipment around the world connected to our digital technology,” said Murphy. “As more customers embark on their digital journeys, interoperability will be a requirement. We are proud to leverage our experience to drive digitalization further in the mining industry.”

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

Sandvik is preparing to deliver its renewed giant, the Sandvik LH625iE electric loader, to field testing to the Kiruna mine in Northern Sweden. The unit to be tested is the 600^th electric loader from Sandvik, and is custom-designed to meet the needs of the Kiruna mine (Figure 2).

The giant underground loader, which features a 9.5 m³ bucket and 25,000 kg payload capacity, is designed to operate in the world’s largest underground iron ore mine, located in Kiruna, Sweden. The basic design of Sandvik LH625iE is well-proven, as Sandvik has been delivering electric loaders powered by a trailing cable for more than 35 years. In addition to utilizing the proven design and robust structures, today’s Sandvik LH625iE belongs to its i-series, featuring advanced technology, latest digital solutions and smart connectivity. As examples of the loader’s intelligence, the new Sandvik LH625iE is equipped with Sandvik Intelligent Control System and My Sandvik Digital Services Knowledge Box™ as standard, and to fully utilize the enormous capacity it offers, the loader can be fitted with Sandvik’s Integrated Weighing System (IWS), as well as AutoMine® and OptiMine® solutions.

Due to the impressive dimensions of the Sandvik LH625iE (total length 14 m, bucket width 4 m, cabin height 3 m), the operator’s compartment is also able to benefit from a roomy, ergonomic design: for example, the spacious cabin is equipped with a unique 180 degree turning seat which significantly improves operator ergonomics because it can be turned to face in the direction of travel rather than requiring over-the-shoulder visibility. The upgraded Sandvik LH625iE has an IE4 classified energy-efficient electric motor, with a further significant improvement being the totally new, low-tension reeling system to increase the trailing cable’s lifetime.

The collaboration between Sandvik and LKAB’s mine in Kiruna dates back 20 years, during which time Sandvik has delivered a total of 28 loaders. “We are satisfied with the loaders delivered from Sandvik, with 14 still in production today. We have had a long and good collaboration and look forward to a good continuation”, says Michael Palo, Senior Vice President, Northern Division at LKAB.

Sandvik LH625iE is living proof that it is possible to achieve enormous carrying capacity and productivity without the use of traditional diesel engines and fossil fuel. The newcomers, battery-electric loaders, also reinforce that message, with Sandvik receiving positive results from its testing of Artisan A10 battery-electric loaders in Canada. Artisan A10 is the most capable loader in its size class, able to carry 10 tonnes whilst retaining its outer dimensions equal to those of current 7 tonne diesel loaders.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

Sandvik Mining and Rock Technology presents two years’ worth of upgrades on the remote-controlled Dino^TM DC400Ri surface top hammer drill rig for urban areas and other applications calling for excellent mobility. The upgraded rig, renamed Dino™ DC410Ri, offers significant improvements in electrical and mechanical reliability, 15% higher tramming power and a large number of smaller but nonetheless important updates for improved reliability and productivity.

Dino DC410Ri is a major all-around upgrade from its predecessor Dino DC400Ri, originally launched in 2014. A compact machine for 51 to 76 mm (2 to 3”) hole sizes, Dino DC410Ri continues to offer mobility and stability for contractors tackling cramped urban construction sites, as well as for demanding quarry and infrastructure applications. The remote radio control, 14 kW RD414 rock drill, advanced i-series torque control system and up to 18 square meter (193 sq ft) coverage area add up to a cost-effective and productive solution for demanding jobs.

While retaining the basic design of the original machine, Dino DC410Ri features a number of significant upgrades for improved reliability. Its entirely new electrical system responds to challenges with components such as I/O boards. Several mechanical details have been reinforced, including a steel-framed tramming support for the feed beam and ruggedized rod-handler arms.

The upgraded Dino DC410Ri offers enhanced mobility thanks to 15% higher tramming power compared with the previous model. Other features contributing to excellent mobility include low tramming height, low center of gravity and high ground clearance.

A range of new options available for Dino DC410Ri create even more possibilities to customize the rig for various applications. NoiseShield-DC is a simple and compact noise-reduction solution for Dino DC410Ri, offering up to a −7.5 dB reduction in A-weighted sound pressure within a 16-meter radius of the drill rig. The isolation panels of this patent-pending system are easy and quick to install simply by replacing the standard mesh panels of the safety cage.

Contractors aiming for minimum set-up times can select the feed auto-aligning option, which maintains the alignment of the feed beam at the preset angle even if the position of the boom changes from one hole to the next. Water flushing can be a useful option for applications requiring optimal dust suppression, such as tunneling jobs.

A tangible improvement likely to be appreciated by many operators is the new remote-control unit (Figure 2). It has redesigned joysticks for easier handling with work gloves on, the plastic wiring connectors have been replaced with metallic military-grade components, and the control unit is better protected against moisture leaks in tough, cold environments.

Another practical feature is the possibility to duplicate the drilling control display on an Android phone or tablet. The remote screen, attached to the remote-control unit, gives a perfect view of the drill rig alignment and displays the drilling and tramming parameters for easy and accurate control, even if the rig itself is on the bottom of a deep trench or close to the edge of a hazardous bench.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

Sandvik Mining and Rock Technology, Tampere/Finland, introduces two new innovative solutions to reduce noise emissions in surface top hammer drilling (Figure 1). The new options for Ranger™ DXi series and Dino™ DC410Ri surface drill rigs help to mitigate harmful noise at construction worksites and quarries.

Many contractors and quarries face increasingly restrictive noise limits, particularly in urban areas. Effective solutions are necessary to cut out harmful noise to improve work safety and to maintain neighborly relations with local communities. The new solutions introduced by Sandvik are not only beneficial to the surrounding areas, they also reduce operators’ and worksite personnel’s exposure to harmful noise levels, thereby offering a more comfortable working environment.

The main source of noise from a top hammer drill rig is the rock drill itself, which accounts for up to 75 % of the total sound power level from a drill rig. Both new Sandvik solutions reduce the sound level around the drill rig by isolating the rock drill and rod handling system inside a noise-suppressing structure. These solutions are especially effective at suppressing the most disturbing drilling noise frequencies, between 2,500 and 10,000 Hz.

NoiseGuard-DXi reduces noise emissions from Ranger™ DXi series drill rigs (max. 27 kW rock drill, recommeded hole diameter 51 to 27 mm / 2″ to 5″) designed for construction applications and quarries. NoiseGuard-DXi is a fully enclosed structure that provides up to 12.9 dB noise reduction in A-weighted sound pressure within a 16 m radius of the rig. In this measuring distance, the noise reduction compared to unmitigated sound pressure is up to 95 %. The NoiseGuard-DXi option comes with a camera system that provides visually aided drilling when the structure doors are closed. Additionally, it has an innovative single-bolt dismantling design for fast and easy maintenance on the feed system.

Another Sandvik innovation, NoiseShield-DC, is a simple, compact solution for the smaller, cabinless Dino™ DC410Ri drill rigs (14 kW rock drill, recommeded hole diameter 51 to 76 mm / 2″ to 3″) that excel in urban worksites. While not fully enclosed, NoiseShield-DC offers up to a 7.5 dB reduction in A-weighted sound pressure by directing the drilling noise upwards through an open top, away from the operator and surrounding areas. This reduction translates to an 82 % mitigation in noise pressure within a 16 m radius of the drill rig.

For noise reduction for the classic Ranger™ DX series drill rigs, a solution called NoiseGuard-DX has been successful in the market for several years.

Requirements to limit noise from drilling machinery stem from several international and national sources, such as EU directives, various safety standards, occupational health and safety legislation and environmental regulations. The measurements above represent the A-weighted sound pressure (LpAd) levels according to the EN 16228-1 safety standard, which applies the methods standardized in SFS EN ISO 3744:2010 for determining the sound power level of a noise source.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

The new Sandvik 800i series of premium cone crushers (Figure 1) features mechanical upgrades, connectivity, advanced automation and rebuild possibilities to predict performance, maximize uptime and offer the best in sustainability at the lowest possible cost.

Including three new models, CH830i, CH840i and CS840i, the 800i crusher series has been improved and extended to offer reliable, intelligent crushing to any mining or aggregate application. Connected to My Sandvik, Sandvik 800i crushers enable managers and operators to make decisions based on facts, and see areas for improvement directly, increasing uptime and availability.

The 800i connected crusher series features the new generation Automation and Connectivity System (ACS) as standard. The system continuously monitors and optimizes crusher performance and controls the complete lubrication system, increasing uptime and reliability. The 800i series has been toughened and improved to offer greater reliability, higher availability and a low risk of critical failure.

All 800i crushers come with the new generation ACS, and are connected to the My Sandvik portal. This allows managers and operators to access and manage all the vital information they need to make informed decisions. My Sandvik can be accessed using a smartphone, tablet or computer.

Bolted rather than welded top and bottom shell liners make changing 90 % faster. The over-pressure system keeps dust out, and the standard offline filter keeps oil cleaner, extending oil life by up to five times. More power output from less energy and more uptime through intelligent crushing make the 800i series a safer, more sustainable choice.

The 800i crusher series can be purchased as a completely new crusher, or you can choose a Sandvik REBORN solution, replacing an existing crusher and reutilizing existing auxiliaries and infrastructure. This plug and play installation minimizes disruption and maximizes productivity, while offering up to 40 % cost savings compared to a complete crusher system.

Sandvik´s service agreements provide customers with safer operations, low operating costs and long service life, unlocking the full potential of their crushing plant 365 days a year. It increases productivity by up to 10 %.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

iSURE^® underground rock excavation software is a purpose-developed excavation process control tool for providing instrumented face drilling rigs with all the necessary information for optimized drilling & blasting (Figure 1). iSURE^® works seamlessly with Sandvik’s iSERIES drilling rigs, combining pull-out analysis with the rig’s data collection tools and providing an accurate analysis functionality to improve the work cycle and process. The latest version, iSURE^® 8.0, has many new features and tools to further assist geological interpretation.

iSURE^® software (Intelligent Sandvik Underground Rock Excavation software) is a computer program for tunneling, construction and mining drill and blast process control, producing all the data needed for optimizing the drilling and blasting cycle.

Among other design tools, iSURE^® 8.0 has a template-based drill plan generation tool that takes into account rock blastability, tunnel profile, quality target and explosives used. The key lies in the fact that successful operations consist of four essential points – quality, cost, schedule and safety – and iSURE^® 8.0 is designed to help ensure that the best results are achieved, by making drilling and blasting even more accurate.

Optimization of drill and blast means taking into consideration the changes in rock blastability and other changes in the environment. An effectively-controlled blast results in good pull-out, a restricted fracture zone and greater rock strength around the tunnel. Furthermore, rounds’ length and detonation can be tuned to the permitted vibration level and geology. iSURE^® 8.0 helps to achieve this, as it provides a set of plan templates for editing and feedback functions to achieve the best possible result from the blast, with blast patterns being easily edited to match the design parameter.

iSURE^® 8.0 enables drill rig usage and drilling process efficiency to be maximized, assessed and measured on a round-by-round basis. Counters for percussion, power pack, drilled meters and net penetration, as well as average and gross drilling capacity (m/h/boom), are collected for each boom. A round’s duration is divided into main categories for navigation, drilling, boom control, idle time, or booms not finishing the job at the same time, further allocating them into sub-categories for drilling and boom. This provides valuable feedback that helps to finetune the rig’s behavior, while also acting as a learning tool for operators.

The program further assists in the analyzing of data collected along tunnel line, which reveals the trends of various KPIs. In addition, analyzing the “measure while drilling” (MWD) items give a histogram report of the achieved penetration rate for the used drilling power, flushing sufficiency or disturbances in drilling, both in general terms and each boom.

All of these features are achieved through the full-featured iSURE^® 8.0 software utilizing the drill rig’s data collection, thereby improving the work cycle and the drill and blast excavation process. It also has an optional toolset for geological analysis (iSURE^® GEO), a tunnel profile 3D scanning system (iSURE^® 3D SCAN) and an interface to a third-party blasting vibration feedback system.

Optional onboard scanner records the tunnel profile at the face. iSURE^® 8.0. creates surfaces based on scanned point clouds with a 3D view with under/overbreak visualization and a 2D view for feedback to drill and blast design optimization, along with production in numbers (realized, theoretical, under/overbreak m³).

GEO option includes rig and iSURE calculation and produces geological mapping information based on the drilling data. Parameters like Sandvik drilling resistance factors (MPa), rock mass fracture indicator, rock classification are calculated and extrapolated. 2D tunnel map views and 3D with cut planes are presented.

Sandvik’s avowed aim is to provide drill and blast tunneling and mining professionals with an updated version of iSURE^® each year. This is being done to reflect the constant changes faced on a daily basis, as well as to reflect Sandvik’s close, integrated relationship with its customers. Based on feedback from users and experience gained during operations throughout the world, the new version of iSURE^® 8.0 now comes complete with:

• wizard-tool to select ready-made drilling templates for drill plan creation;
• cloud system to share data;
• new user interface;
• new license system;
• excavated profile target quality;
• drilling rate index based estimate calculation for cycle (round) time.

New inbuilt cloud based data sharing helps to spread the project data between the group members. Cloud data is owned and controlled by rig owner, defining roles and access rights for members.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

Basalt production has increased by 20 % since Vogelsberger Basaltwerk modernized its processing plant by installing a new high-reduction secondary crusher.

60 km northeast of Frankfurt in south-western Germany, Vogelsberger Basaltwerk GmbH & Co. KG (VBW) extracts basalt from a 19 million year old formation beneath the Vogelsberg mountain range, Central Europe’s largest contiguous volcanic region (Figure 1). VBW produces gravel, stone, sand and other raw materials primarily used as aggregate for asphalt and concrete. As demand for the company’s basalt products has increased over the years, so have the strains on its all-important processing plant.

After more than 30 years of secondary stage service, VBW’s S1650 cone crusher had reached its capacity limits by 2016. Managing Director Bernd Krempel and -Dieter Pracht, operations manager for VBW, researched a replacement with a higher reduction ratio, a crusher that would not only increase capacity but also improve product quality.

VBW initially intended to replace the outdated S1650 with a Sandvik CH-series cone crusher, which would have required a reduction in both feed size and overall throughput.

Sandvik soon announced the launch of Sandvik CS550, and the new crusher’s design immediately impressed Krempel and Pracht. “It’s basically a hybrid of assessed models, a flat cone crusher and gyratory crusher,” Krempel says. Capable of operating at higher pressures than other Sandvik CS-series crushers and featuring proven components from Sandvik CH-series models, Sandvik CS550 seemed to be the ideal solution for VBW.

Sandvik ran process simulations in September 2016 with its PlantDesigner software, using VBW’s real-life figures for work index, basalt moisture, bulk density and clay percentage. “That simulation process was very important for us,” Krempel says. “The competence of our contacts at the company helped convince us.”

Despite having been convinced of the new crusher’s suitability for his operation, Krempel admits he still had nerves about being the first Sandvik CS550 user. VBW commissioned its Sandvik CS550 in February 2017 and soon saw a notable increase in the plant’s throughput capacity (Figure 2).

“The biggest advantage, and the one we hoped to have, is the high reduction ratio, and the smoother running of the process,” Pracht says. “We can now achieve higher performance with the downstream pressure because we have less return flow. And in contrast to competitors’ products, it has the largest possible intake.” Less recirculation resulted in reduced wear and less downtime.

“The costs fell, both with the actual crusher and with the downstream components like our gyratory crusher for producing double-broken chippings,” Krempel says. “Because we’re able to supply it with smaller pieces, the costs in wear and in electricity have significantly decreased,” he says.

Sandvik CS550 features a redesigned crushing chamber to ensure improved product quality. VBW feeds 250 to 300 t/h of 250 to 350 mm primary crushed material into the crusher’s C-chamber intake. More than 80 % is processed to VBW’s preferred particle size of < 32 mm.

Pracht says Sandvik CS550’s control system has major advantages over its retired predecessor. It only takes a few simple steps to adjust the crusher to different grain sizes. “Compared to the old crusher, we now have much more flexibility,” he says. “We can adjust our processes more quickly to meet the needs of our clients and to meet demand. We bought the CS550 in order to produce finer aggregates. But at the press of a button, we can adjust the cone, and we have coarser material immediately. There is nothing better on the market right now.”

After more than two years of operation, the crusher’s reliability remains as vital for VBW as its productivity.

With its Sandvik CS550 at the center of a more productive processing plant, VBW has shifted its focus to exploring other potential optimization opportunities. Its primary crusher, e. g., can barely keep the new Sandvik crusher 50 % fed despite operating at its performance limits.

Despite the primary stage bottleneck, VBW has increased basalt production by 20 % since installing Sandvik CS550, even operating the crusher at the smallest possible throw of 24 mm.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

Joint clients of IBM and Sandvik Mining and Rock Technology, Stockholm/Sweden, one of the world’s largest premium mining equipment manufacturers, are tapping the powers of IoT, advanced analytics and artificial intelligence to realize safety, maintenance, productivity and operational efficiency.

The mining and rock excavation industry is under growing pressure to increase the global supply of minerals to meet the needs and expectations of a rapidly rising world population. This often requires extracting from increasing greater depths, which can make it difficult to communicate and act as necessary when equipment fails or needs to be serviced.

OptiMine® Analytics transforms data into process improvements via predictive insights and actionable dashboards embedded into operation management systems. Using the analytics capabilities from IBM Watson IoT, this information management solution allows mining companies to combine equipment and application data from disparate sources in real-time, analyzing patterns in the data to help improve availability, utilization and performance (Figure 1).

Through a series of IBM Design Thinking workshops, IBM and Sandvik work with clients to develop a framework to shape offerings around data driven productivity and predictive maintenance. Using the Watson IoT technology, Sandvik and IBM have jointly created a platform able to comply with the stringent reliability and security requirements of mining operations. Predictive maintenance technology leveraging IoT sensor data has also been introduced as part of this platform.

“Proactively identifying maintenance needs before something breaks is leading to huge cost and time savings,” said Patrick Murphy, president, Rock Drills & Technologies, Sandvik. “Our award-winning OptiMine® Analytics with IBM Watson IoT solutions offer our customers a more complete view of their operations for smarter, safer and more productive work.”

Sandvik and IBM clients such as Petra Diamonds and Barminco are using IoT to help reduce miner exposure to hostile work environments and increase safety.

“Our top priority is the safety of our employees and if a machine fails underground we need immediate insight into what is happening in that tunnel,” said Luctor Roode, executive operations at Petra Diamonds. “With the solution from Sandvik and IBM, we have real-time data that allows us to immediately identify the root cause of the problem and act accordingly.”

“Leveraging data is become increasingly valuable across the mining sector. Through analytics, machine learning and AI, we are seeing new possibilities for increased operational efficiency,” said Paul Muller, chief executive officer, Barminco. “Our partnership with Sandvik’s OptiMine® Analytics allows us to fast-track our efforts, leveraging Sandvik’s whole-of-fleet data and innate machine knowledge.”

OptiMine® Analytics will also be used by Vedanta Zinc International’s Black Mountain Mining (BMM) operations in South Africa’s Northern Cape Province, to accelerate data-driven operations for safety, efficiency and productivity for trucks, loaders and drills. Additionally, Hindustan Zinc, one of the world’s largest integrated producers of zinc, lead and silver has tapped Sandvik to implement a major digital transformation at its Sindesar Khurd Mine in India, to ensure all required infrastructure and platforms can achieve world-class mining safety, efficiency and productivity.

“Sensors and tracking systems for asset management is only the beginning when it comes to how artificial intelligence will disrupt the mining industry,” said Jay Bellissimo, General Manager, Cognitive Process Transformation, IBM Global Business Services. “Creating a solution that turns the data into actionable insights is a delicate matter. It requires an interdisciplinary effort spanning across mining technology, software engineering and data science. IBM and Sandvik are now on course to help transform the mining value chain with the fusion of cognitive capabilities into miners business and operating processes.”

Sandvik has been delivering solutions in the mining automation business for decades, with autonomous operations in more than 60 mines on six continents. This footprint is a major asset to the process optimization solutions in higher and higher demand. For its part, IBM has been working with leading mining clients to infuse cognitive capabilities in their business and operating processes, creating the Cognitive Value Chain for Mining. This multidisciplinary approach leverages and expands on the concepts of the fourth industrial revolution by helping miners achieve new efficiency savings, without having to make large-scale capital investments.

Further information:
Sandvik Mining & Rock Technology
www.rocktechnology.sandvik

Many medium-sized companies in Germany also form the economic foundation and hold their ground in the tough competition in the extraction and processing of rock products. A typical example is Otterbein Zement- und Kalkwerke GmbH & Co. KG, located in Großenlüder-Müs, north-west of Fulda in the state of Hessen. The family business has been extracting around 500,000 t/a of shell limestone at this quarry since 1889. As the experienced manager of the quarrying business, who has himself been drilling at Otterbein for more than ten years, Bernhard Pfohl is well aware of the importance of using the right machinery. The decision in favor of the Sandvik Ranger DX800 surface top hammer drill rig therefore met a crucial need for a high level of professionalism. “We cannot afford to make any mistakes, particularly in investing in such a niche technology,” says quarry manager Pfohl, adding: “We maintain only one drill rig, which as an indispensable key piece of equipment represents a kind of bottleneck at the start of the production chain.” That being so, the company did not take the decision in favor of the new drill rig at the start of this year lightly, and short-listed a total of three competitors. The Sandvik Ranger DX800 (Figure 1) also came out on top because the operating conditions at Otterbein in Großenlüder-Müs are anything but simple.

The geology in the quarry is extremely complex, with closely alternating dips of intensively disrupted layers. Associated with this geology there are often crevices and fragmentary edges on the work horizons. As an outstanding unique feature, the Ranger offers a superstructure that can revolve up to 180°. This is a function that Pfohl puts to use in daily practice. “By swivelling the rig I can cover a substantial working area of up to 26 m² without having to shunt laboriously in the danger area close to the tearing edges. As a result, a substantially greater distance from the abyss can be maintained, and yet I have an optimum view of all the drilling points.” The irregularity of the layers means that the quarry manager is repeatedly faced with fluctuating specifications. In addition, the range and mobility of the Ranger DX800 at the drilling point are expanded by the standard articulated drilling arm. The extraction concerns the whole sequence of shell lime. Widely varying types of rock with extreme differences in consistency are added to geology that is already complex. For this reason, Pfohl chose the version with HF820T optional high-frequency hammer, with which drift output can be increased by up to 10 % if necessary. When, at the other extreme, such soft layers are encountered that the drill rod sags downwards, so that the drilled material cannot be removed quickly enough, the automatic idle blow protection of the Rock Pilot+ control unit comes into effect immediately.

Operating conditions at the Otterbein quarry are made even more difficult when slippery surfaces form in the quarry after rainfall. Pfohl is able to improve the stability of the rig effectively using the optional extendible solid prop on the chassis. In addition, the superstructure can be tilted hydraulically against the crawler frame in the direction of travel to ensure displacement of the center of gravity for optimum stability. “As well as in drilling, I utilize this option in resetting the rig, when I can align the superstructure against the vertical on the steep slopes,” the quarry manager explains. This greatly assists the driving safety and mobility of the Ranger DX800. Despite the solid construction of the most important components, with a total weight of just 16 t the rig is easy to transport and easy to shunt on the crawler chassis. The comprehensive concept goes into details here. The standard safety equipment of the Ranger DX800 also contains a newly developed protective cage on the mount (Figure 2), with which Sandvik closes the gap in possible sources of danger on the moving parts. Unintended intervention in the circulating operating process can thus be reliably prevented.

The procurement of a drill rig is an investment for at least 10 years – equipment should preferably last twice as long. “The Ranger DX800 makes a convincing case there too,” says Pfohl. “Sandvik supplies everything from a single source, so long-term maintenance from a single source can also be relied upon. With one welcome exception: Warranty and servicing of the cat motor are dealt with by the local Zeppelin dealer, which also looks after our cat equipment.”

Further information:

Sandvik Mining and Construction
Central Europe GmbH
www.rocktechnology.sandvik

When it comes to the preparation of mineral raw materials, Sandvik AB, Stockholm/Sweden is renowned for its world class crushing and screening technology. Perhaps it is less well-known that Sandvik also has an outstanding range of screening media. We can expect this to change based on the positive customer feedback Sandvik is now receiving on its new WX7000 screening media.

The operating hour monitor was reporting exactly 1.632 h of operation when Selim Sahin, Sales Manager Sandvik screening media & wear protection in central Europe, dropped by at the Bischofsheim plant of Basalt AG on 4th October 2017 to reassure himself that his promise was standing the test. Sandvik’s new WX7000 screening media had been installed in the lower deck of a screening machine at the plant in March 2017 (Figure 1). Since then, operators have been carefully monitoring this efficient, anti-blinding, tensioned screening media which is made from wear-resistant polyurethane. So far, they are seeing excellent screening results.

The decision to change to the WX7000 screening media from the previously used wire mesh media was a result of a long and close partnership with the customer. The plant underwent extensive modernization during 2011/12 and, following in-depth discussions with Sandvik, several Sandvik cone crushers (Sandvik CH660, Sandvik H440 and Sandvik H3000) have taken over preparation of the pre-crushed basalt in the post-crushing stages.

During discussions regarding the winter repair program, the customer mentioned he was frequently experiencing difficulties changing the media on the lower deck of the screening unit. Taking note of production conditions and required parameters, Sandvik WX7000 tensioned anti-blinding polyurethane screening media was suggested as the solution. Alongside the guaranteed wear life offered by the manufacturer, operators were also reassured by the professional approach of Sandvik’s experts. These two factors combined led to the decision to install the WX7000 screening media.

A specialist Sandvik screening media development team made the journey from Sweden to change the screening media on the lower deck of a 12 m² circular vibrating screen, which had been in service for a long time. They examined the material feeding section and evaluated the existing grading analyses. After a detailed investigation, they recommended an overlapping, longitudinally tensioned version of WX7000 for the screening deck. Finally, the hole pattern was accurately defined to avoid misplaced particles and to produce a clean target granulation, with as few undersized particles as possible.

Deputy Plant Manager Burkhard Kunze was very impressed by how easy it was to install the flexible WX7000 screening mats. In the past, routine changes of the rigid wire mesh on the lower deck were arduous and physically demanding, an even greater burden due to the required frequency of the media changes. The plant stood idle for at least half a day every ten to twelve weeks due to the need to change the wire mesh. Various attempts to switch to harp or rubber had failed, due to quality and/or wear issues. The desired aim to reduce wear, prolong change cycles and maximize product quality could only be achieved with Sandvik WX7000.

Operators have stated that the considerable increase in wear life is already having a positive effect on operating costs. After a detailed analysis it has confirmed that it has already been possible to measure the direct utilization value of the process.

When inspecting the screening media after six months’ use, it showed no weaknesses, no clogging and no initial visible signs of wear. The wear-resistant polyurethane-material is designed both for fine screening and for harsh operating conditions. Integrated steel cable reinforcement minimizes both stretch and the resulting risk of out-of-control flutter, guarantees secure attachment and lengthens adjustment intervals. The polyurethane material’s flexibility prevents the holes from clogging. They are punched out in various geometrical shapes and are exactly matched to the required task.

Further information:
Sandvik AB
www.sandvik.com