Sandvik Mining and Construction Central Europe GmbH

With effect from 1st June 2018, Friedrich Hirt­ler has been appointed Managing Director of Sandvik Mining and Construction Central Europe GmbH, Essen/Germany, having taken over this management role on an acting basis back in December 2017 alongside his permanent position of Sales Manager Parts and Services. In his new position, he is simultaneously a member of the management team for Sales Area Northern Europe. Hirtler reports directly to Ulf Johansson, Vice President Sales Area Northern Europe at Sandvik Mining Rock Technology.

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

The Büdingen-Rinderbügen quarry in Wetteraukreis/Germany, has been supplying the basalt that is characteristic of the Vogelsberg landscape since 1963. The basalt is currently quarried and reduced to gravel, chippings and fine flint, as well as crushed sand, by Vogelsberger Basaltwerk GmbH & Co. KG (VBW), part of the Dressler Verwaltungsgesellschaft mbH group of companies. The group, now managed by Fritz and Klaus Dressler, is regarded as one of the leading names in construction planning, civil engineering, road construction and development. The group has also secured added value in materials production through its raw materials subsidiary VBW, under the slogan “The birthplace of construction”. The basalt grit is used by VBW to produce construction materials to meet the requirements of several customers in the region.

Bernd Krempel joined Dressler as co-director at the beginning of 2016. One of his most important tasks is continuous optimization of the basalt plant process. The first step of the modernization programme was to replace the secondary stage crusher – a 1650 cone crusher that had been in operation since 1984 – with the aim of improving capacity and product quality. Always satisfied with the service and support from Sandvik, VBW’s decision makers favoured replacing the crusher with a Sandvik CH-series Hydrocone, even though they knew this decision would also impact operation of their primary crusher. However, at just the right time for VBW, Sandvik announced the new CS550 that was even more ideal for their requirements.

Just to recommend, never mind purchase, a brand new innovation requires a deep, mutual trust. With no lack in trust between the consultancy partner, stationary crusher specialist Hubertus Kirschbaum from Sandvik Mining and Rock Technology’s sales team in Essen and those involved at VBW, the advice was spot on. Results of quarry testing in Sweden of the pre-series models of the new Sandvik CS550 spoke for themselves. This latest, innovative cone crusher from the 500 series not only complements the two existing Sandvik CH550 and CH540 models, it’s also an alternative for the popular CH660. The Sandvik CS550 uses a range of familiar components from the proven CH crushers and operates at higher pressure levels compared to traditional CS-crushers, has low-maintenance and many safety features and is less sensitive to material feed variations, e. g., a secondary crusher from the CH series. The reliable and powerful secondary crusher with its high reduction ratio comes with a completely redesigned crusher chamber, which essentially guarantees the enhanced quality demanded at the secondary crushing stage. To meet the demands of the customers, the C (coarse) crushing chamber is designed for intake of materials with a feed size of up to 350 mm, while the EC (extra coarse) crushing chamber can handle up to 430 mm.

German customers were given the first opportunity to inspect the new crusher at close hand at an event in September 2016. The crusher was commissioned, and installed in February 2017 as a replacement for VBW’s outdated predecessor (1650 crusher) (Figure 1).

The eminent suitability of the CS550 as a viable alternative to the CH-series for secondary stage crushing at VBW quickly became clear. The large C-chamber intake to match the jaw crusher in the primary stage quickly “swallows” the crushed material of 250 to 350 mm in feed size, and thus offers the possibility to produce large volumes of the final grain fractions even at the secondary stage, while ensuring a high reduction ratio and an excellent shape of the end product. Between 250 and 300 t/h of material can be processed, with seemingly no effort, to the target particle size of 0/56 mm, with the proportion of the preferred particle size of < 32 mm being around 80 %. The wide range of additional settings, together with additional, larger throws of 24/28/32, 32/36/40 and 40/44/48 mm provides processing flexibility if this should be needed. The reduction of fine material that is required is a strikingly positive feature compared to the old crusher. The Sandvik CS550 also clearly meets VBW’s requirements in terms of oversized particles > 32/X.

Overall, the new secondary crushing stage therefore allows a more efficient process with a significant reduction in the recirculating load, while at the same time relieving the tertiary stage of some of its load. This allows the operators more time to quality assure the product. This was an essential element of the modernization plan.

Further information/Weitere Informationen:
Sandvik Mining and Construction
Central Europe GmbH
www.sandvik.com

Salt production here dates back to the Middle Ages, when brine was evaporated from open pans. Today, esco (european salt company) with its headquarter in Hanover/Germany, relies on modern mining equipment to extract rock salt from an underground deposit formed 250 million years ago.

Mining is ingrained in the history of Bernburg, a town of 35,000 in eastern Germany that sits along an old medieval trade route. The Bernburg salt plant is a key economic driver in this area surrounded by industrial operations. Bernburg was integrated into K+S Group subsidiary esco in 2002 and is now the largest of esco’s three German production sites. The company has invested nearly 170 m e in modernizing the operation in recent years. Today, Bernburg’s mine fields cover an area of around 40 km² – more than two-thirds the surface area of Manhattan in New York City – and the plant produces 2 m t of salt annually.

esco in Bernburg looked for a supplier who was able to provide a loader that satisfied all their emissions, economic and productivity criteria. Because productivity is the main thing they decided to buy the biggest loading machines from Sandvik with a bucket size of 14 m³. That means 21 t in one shovel. So Bernburg recently bought two of these Sandvik LH621s, the supplier’s largest diesel loader, to replace aging competitor equipment (Figure 1).

Sandvik LH621 had previously proven itself in mines in the United States operated by Morton Salt, another K+S group subsidiary. The Bernburg mine also took into consideration the model’s performance at salt mines in western Germany and a potash mine next to Bernburg.

The cleaner Tier 4 Final engine in Sandvik LH621 was also a key factor in selection. Tier 4 Final is a new technology for the mine but it is necessary to do all to keep the employees healthy and comply with EU emissions regulations. The new loader quickly became an operator favourite. The Sandvik LH621s are the mine’s first loaders with a closed cabin, minimizing operators’ exposure to noise, heat and dust.

“I am impressed that the loader is quite fast, simply regarding the hydraulics and performance, and the air conditioned cabin, especially in the stopes and drifts, where it is dusty and warm,” says operator Davis Protzmann. “There one can operate the loader marvellously. All in all, it is impressive to operate such a huge loader. When I reach the muck pile, the bucket is full immediately.”

Meanwhile Bernburg received its third Sandvik LH621.

Further information/Weitere Informationen:
Sandvik Mining and Construction Central Europe GmbH
www.sandvik.com

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