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

RockPulse™, a new technology and product introduced by Sandvik Mining and Rock Technology, is the first practical solution for real-time tool stress monitoring in top-hammer drilling. The add-on system integrates directly with the rock drill and its control system, and can be used for drilling process optimization in varying rock conditions. This also helps to reduce the stress fatigue of drilling tools. RockPulse™ offers significant potential to improve overall drilling performance, by as much as 5 %.

Profitable rock drilling requires balancing between drilling power and cost-efficiency. While use of high drilling power is required for good performance, excessive power becomes counterproductive due to high stress levels and wear of drilling tools. Optimization of tool stress and consequently tool lifetime are essential for cost-efficient drilling operations. Conventional drilling control technologies have done this based on indirect performance indicators only, such as percussion or feed pressures.

RockPulse™ analyzes each piston blow in real time to extract data on the tool stress. This enables operators to optimize drilling power and to minimize inefficient use of percussion energy. Stress waves created by piston strikes are measured continuously using sensor technology developed and patented by Sandvik. The system consists of a Sandvik shank adapter and rugged contactless sensor inside the rock drill. Stress wave signals captured by the sensor are analysed within the Sandvik SICA control system of drill rig. The system is available for new Ranger DXi drill rigs and RD920 series rockdrills (Figure 1).

“Our tests from real-life conditions show 5 % increase in average penetration rate, even though the percussion power was decreased by 4 %. Drill operators have additionally commented that RockPulse helps them to optimize bit regrinding intervals and thus boost efficiency and productivity,” says Jarno Viitaniemi, Product Manager, Surface Drilling, with Sandvik Mining and Rock Technology.

RockPulse™ user interface visualizes and alerts on three key parameters: drill bit response, tools load and feed level. Drill bit response helps to minimize the strain on the tools by indicating how much of the impact energy is used for breaking rock and how much is reflected back to the tool string. Tool load indicator shows the tensile stresses affecting on the tool string, which helps to avoid underfeed in weak rock and excessive wear of drilling tools. Feed level indication shows whether drilling is being done within the specified feed range – a key parameter for excellent hole quality and long tool life.

Further information:
Sandvik Mining and Construction Central Europe GmbH
www.rocktechnology.sandvik

Rammer was in 2018 celebrating 40 years of excellence. In order to help celebrate this momentous occasion, and to reflect changing customer requirements, it has renewed both its outlook and product offering. This has led to the updating and upgrading of its Excellence Line of hydraulic hammers.

Following on from the launch of the Performance Line of hydraulic hammers earlier in 2018, Rammer has launched the updated and upgraded Excellence Line (Figure 1). This range of hydraulic hammers reflects Rammer’s desire to renew its offering and outlook through focusing on changing customer requirements. Hence one of the key features of the new Excellence Line is that safety is endemic – with all models featuring reflective stickers, e. g., to the operation of the range, no matter if the hammer is being used in quarry, demolition project, tunnel or any other application.

One of the major features of the Excellence Line is Rammer’s purpose developed RD3 remote monitoring device – a first of its kind on hammers. RD3 uses the MyFleet Telematics service to track and monitor fleet equipment usage without the need of going to the site to collect the data, being ideal for dealers, rental companies and operators. This cloud based system enables the hammers to be viewed and monitored in Google maps.

The main benefits of the system are that it enables owners and managers of fleets to know exactly where their equipment is, and how it is being used. This facilitates better business decisions through providing improved security and optimized fleet location, whilst enabling enhanced application knowledge and operator education, all accomplished via GPS data, contributing to the overall profitability of the business.

As well as RD3, the Excellence Line reflects Rammer’s developing customer focused outlook through having a host of other new features. Lower tool bushing rotating and replacement on the field increases lifetime of lower tool bushing, which contributes to reduced operating costs. This is further reflected through the use of two tool retaining pins that increase the lifetime of the tool and retaining pins, as well as increases the lifetime of the tool bushings. An IBP on/off selector is fitted to the valve body enabling easy field adjustments (2577E and up). Separate greasing channels from the valve body to the upper and lower tool bushing further increases tool and tool bushings lifetime.

Rammer’s Excellence Line continues the company’s 40-year tradition of delivering innovative hammers designed to improve profitability, safety and performance. With their new customer focused features, the line perfectly represents Rammer’s developing outlook in assisting businesses enhance their performance.

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

In recent years, self-driving vehicles have become a popular discussion topic. Sandvik has had automated loaders and trucks working in mines for over 20 years – with zero accidents involving people. To prove its capabilities, Sandvik moved things above ground and put its latest generation of automation to the test.

In a new film, an 11 m long Sandvik LH514 self-navigates through a labyrinth of glass (Figure 1). While glass is clearly a different material to the rock walls the laser sensors are designed for, the loader detects the fragile labyrinth and maneuvers through its narrow aisles. To prove the feat’s realness, Sandvik Group CEO Björn Rosengren takes over the driving at the end of the film and crashes into the glass labyrinth.

“Sandvik automated loaders have been in use for more than 20 years, with over two million operating hours underground,” says Jouni Koppanen, Senior Systems Engineer for Automation at Sandvik Mining and Rock Technology. “Autonomous systems improve safety and productivity for our customers. For the first time ever the entire cycle can be automated, from loading to hauling and dumping. Nobody has been able to do that before.”

For Rosengren, the glass labyrinth test was obviously a special day at work. The unique filmed feat also demonstrates Sandvik’s view on innovation. “Some of today’s most sophisticated technology is found within Sandvik’s different business areas,” Rosengren says. “We’ve always worked close to our customers developing new products and technologies. Going forward we clearly see digitalization as a key area. It will help both us and our customers to be more productive, efficient and sustainable.”

While a glass labyrinth might not be a traditional operating environment for a mining loader, such unconventional thinking has seen Sandvik stay at the forefront of technologies like automation. The AutoMine® system means that Sandvik loaders and trucks learn the safest and most efficient route the first time they enter a tunnel. Guided by a set of lasers, the equipment’s intelligent system maps out and records a path. Sandvik’s patented algorithms, together with its sensors and gyroscopes, ensure the machine knows where to go underground, where GPS is not possible.

Further information:
Sandvik Mining and Construction Central Europe GmbH
www.rocktechnology.sandvik

With effect from 1st June 2018, Friedrich Hirt-ler 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.

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