In the mining industry, compliance with health and safety regulations is essential to protect workers from hazards like respirable crystalline silica. The MSHA Silica Rule, effective June 17, 2024, sets exposure limits and requires measures to minimize silica dust. Scrapetec offers innovative dust control solutions, such as the AirScrape and DustScrape, to help mining operators comply with these regulations. These products reduce silica dust emissions, improve air quality, and enhance worker safety. By using Scrapetec’s solutions, mining operations can also boost productivity and demonstrate a commitment to sustainability and worker health.
ISC IngenierĂa del Sur SAC, the partner company of Scrapetec in Peru, achieved an impressive feat. Within 24 hours, they installed 108 meters of AirScrape and 2 DustScrape systems. The next day, they continued their pace and added an additional 56 meters of AirScrape and 3 DustScrape systems in just 16 hours. The results were remarkable, with effective dust control and spillage prevention at the material transfer points. These fast and efficient installations delighted the customer and showcased the excellence of that partnership in the industry.
The results were nothing short of extraordinary. The AirScrape and DustScrape systems immediately proved their worth, effectively containing dust and eliminating spillage at the customer’s material transfer points. The improved working environment brought about increased productivity and enhanced safety for the employees.
In conclusion, the story of Scrapetec’s partnership in Peru showcases the power of teamwork, expertise, and efficiency. With their AirScrape and DustScrape systems, Scrapetec is transforming material transfer operations, one installation at a time, and leaving a lasting impact on the industry.
Fig. 1. AirScrape – dust free and without belt contact. Photo: ScrapeTec
Downtime, cleaning costs, maintenance, wear and tear of materials or health risks for employees – the cost factors relating to the transfer points to conveyor systems are not unknown, but usually go unnoticed. Whether in mining, in the production of gypsum products or cement. As a result of the cooperation with ScrapeTec, cement plants in Germany have now increasingly discovered the special sustainable effect of the new conveyor skirting for chutes. Manufacturer ScrapeTec does a kind of persuasion with this innovation.
In the first step, usually 1-2 transfer points on the customer’s system are equipped with the new non-contact sidesealing. Then comes the work on the fly. The AirScrape side sealing is usually convincing at first glance, because of the clean working method without dust, spill and maintenance compared to conventionally equipped transfer points. And after 3 months at the latest, the investment has already paid for itself because of the eliminated cleaning and maintenance costs.
In this way, system operators can be convinced that sustainable work can also be implemented easily and efficiently on conveyor systems – thanks to the innovative solutions from ScrapeTec, which, in addition to the AirScrape conveyor skirting, offer even more products for the transfer point in order to work more sustainably (Figures 2, 3).
Fig. 2. TailScrape supplements the AirScrape and seals the transfer for optimum results in the rear area.Fig. 3. PrimeTracker – the new conveyor belt tracking assistant. Counteracts belt misalignment permanently. Photo: ScrapeTec
“The AirScrape<sup>®</sup> has landed” is the title of the new story on the website of Kinder, one of the leading providers for conveyor components in the Pacific region. The impressive progress of the AirScrape® with its contact-free and dust-minimizing mode of operation (Figure 1) has long been observed by Kinder. They were particularly impressed by the YouTube videos about the use of the innovative conveyor skirting. The AirScrape<sup>®</sup> as a side seal and the TailScrape<sup>®</sup> as a rear seal for transfer points effectively complement Kinder’s portfolio in the area of conveyor systems and skirting. With this, Kinder offers its customers in Australia, New Zealand and Indonesia a real innovation in the field of conveyor belt seals, which also promises a high level of cost-effectiveness. In addition to Europe, Africa and America, the AirScrape<sup>®</sup> will now be available in the Asia-Pacific region. At ScrapeTec Trading GmbH from Kamp-Lintfort in Germany, they are proud to have made a “precision landing” in Australia, four years after the AirScrape<sup>®</sup> was launched on the market.
Fig. 1. The first delivery of the conveyor belt seal “AirScrape” from ScrapeTec Trading for the Chuquicamata mine is ready for dispatch. Photo: Scrapetec
ScrapeTec Trading GmbH in Kamp-Lintfort/Germany delivers now to the big players, to the very large mines in Chile. AirScrape, the new contact free seal skirting is listed by CODELCO and was ordered directly from the Chuquicamata mine. CODELCO Chuquicamata is one of the most important copper producers in the world. The performance of the new conveyor skirting “AirScrape” convinced CODELCO and the Chuquicamata mine. With that, they decided to work dust and spillage free, without maintenance and all in all sustainable. That order is ready for the shipment to Chile (Figure 1).
Sandvik is reintroducing its earlier, renowned Toro™ family name for its underground hard rock loaders and trucks, model by model, starting later this year. The Toro™ family name has been recognized by Sandvik underground mining customers for decades and now Sandvik is bringing back the bull, firstly with the large intelligent loaders Toro™ LH517i and Toro™ LH621i (Figure 1).
Toro™, “the bull”, has traditionally symbolized the strength of Sandvik underground hard rock loaders and trucks since the first model was introduced in the early 1970s. Even though the family name has not been used for 15 years, it has never disappeared from the thoughts of the company and many of its customers.
For the new generation of Sandvik loaders and trucks, the Toro™ stands for safer, stronger and smarter. “Safety is at the forefront of our product design and crucial for those who work in or around our loaders and trucks. We also believe that environmentally-sound solutions and sustainability principles firmly belong with safety. Being strong and powerful is at the very heart of the old Toro™. To be robust, reliable and productive in the most demanding of conditions is part of our heritage, and we will keep that with us going forward. Being smart involves seamless integration with Sandvik’s AutoMine® and OptiMine® offering, but it is also about innovation and smart design, e. g., how we arrange maintenance access, improve efficiency and reduce waste. Developing intelligence on all frontiers is, and will be, one of the key elements of the Toro™ going forward”, says Wayne Scrivens, VP Product Line, Load and Haul.
The large intelligent loaders Toro™ LH517i and Toro™ LH621i now come with several design upgrades aimed to further boost productivity, reduce total cost of ownership and improve operator experience. Both loaders can now be equipped with a Stage V state-of-the-art engine, meeting the most stringent current emission regulations. Operator speed assist, a new feature that will be available with the Stage V engine option, specifically supports downhill tramming and preserves the equipment brakes as the Sandvik Intelligent Control System can be set to limit maximum speed. A new traction control system, available as an option, reduces wheel spin and slippage when penetrating to the muck pile, extending tyre lifetime. Finally, a training simulator, Digital Trainer, has been added to the load and haul equipment range, offering a compact and flexible solution for the safe training of operators, with authentic controls and real loader control system.
As matching pairs for the large loaders, the 51 and 63 t trucks will acquire the Toro™ family name amongst the first equipment models. Both trucks have recently been benefitting from several significant design upgrades including, e. g., a new transmission, heavy-duty cooler, AutoMine® for trucks with on-surface navigation possibility and an ongoing Stage V engine trial. “Customer feedback on the i-series trucks indicates that overall maintenance costs have decreased compared to their predecessors, the Sandvik TH551 and Sandvik TH663. We have also received the same customer feedback on LH517i and LH621i loaders. Reducing costs in addition to the already-reported positive operator feedback clearly shows we are on the right track, which befits the Toro™ family”, says Scrivens. The fifth model acquiring the Toro™ family name is the world’s largest payload capacity underground loader, Toro™ LH625iE. The giant features a 25,000 kg payload capacity and is electrically powered by a trailing cable. The Toro™ LH625iE loader builds on well-proven technology, but also features the i-series intelligence needed for connectivity and digital solutions.
Sandvik Mining and Rock Technology augments autonomous mining capabilities through a partnership with Exyn Technologies Inc. Customers will benefit from the unique combination of Sandvik’s world leading digital mining solutions and Exyn’s deep knowledge of autonomous aerial robot systems. “We are committed to empowering a transformation to autonomy in underground mining,” says Patrick Murphy, President of Rock Drills & Technologies at Sandvik. “This partnership will open up unique benefits, build on our industry leading automation offering and drive faster decision-making in mining processes to seize new opportunities for improving production performance.”
Through this partnership Sandvik and Exyn are working together to provide efficient solutions for mapping and visioning underground mines, which will make a substantial difference when it comes to mine locations that are hazardous, hard to reach or conventionally time-consuming to survey and inspect (Figure 1). Sandvik’s OptiMine® combined with data collected by Exyn’s aerial robots creates progressive visualization and information of the mine’s actual environment to increase overall transparency of the mining process. The future collaboration between Sandvik and Exyn will entail research on how to apply and generate 3D views and perceptions of underground spaces autonomously, while leveraging the full potential of Sandvik’s AutoMine® system.
“We are excited about this new partnership with Sandvik as they are recognized as an innovator in the industry and have revolutionized underground mining,” says Nader Elm, CEO and Co-Founder of Exyn. “For the first time, customers will be able to map the entirety of their underground operations, even in dangerous GPS denied environments, while making mining safer and improving productivity. Through this partnership, we hope to empower efficient decision-making for customers and drive towards the vision of fully autonomous mining operations.”
Exyn is pioneering autonomous aerial robot systems for complex, GPS-denied environments. The company’s full-stack solution enables flexible deployment of single or multi-robots that can intelligently navigate and dynamically adapt to complex environments in real-time. For the first time, industries like mining, logistics, and construction can benefit from a single, integrated solution to capture critical and time-sensitive data in a safer, more affordable, and more efficient way.
Sandvik is a world leader in mining automation, implementing digital mining solutions for more than two decades. AutoMine® covers all aspects of automation, from remote and autonomous operation of a single piece of equipment, to multi-machine control and full-fleet automation using automatic mission and traffic control capabilities. OptiMine® is the most comprehensive solution for optimizing underground hard rock mining production and processes. It integrates all assets and people – including Sandvik and non-Sandvik equipment – delivering descriptive and predictive insights to improve operations.
New is the contact-free AirScrape conveyor belt skirting system, which significantly reduces material spill, dust formation and explosion hazards at transfer points and other critical sections in the conveyor chain. Because this system hovers freely above the conveyor belt, skirt friction and belt damage is eliminated and service life is extended (Figure 1).
“The AirScrape system – which encompasses inward facing, hardened-steel diagonal blades – operates according to a new principle where it hovers 1 to 2 mm, on the left and right side above the conveyor belt. These blades deflect larger particles inwards, while using the air-flow of the conveyor belt and conveyed material to create an inward suction, flowing any dust and fine particles back into the product flow,” explains Thorsten Koth, Sales Director, Scrapetec-Trading GmbH, Kamp-Lintfort/Germany. “Through these diagonally fitted blades and the speed of the running belt, air is drawn from the outside inwards As a result, neither the dust nor material can escape. Conventional skirting is pressed against a conveyor belt to keep dust and material in the middle of the belt, but after a period, wear of the skirting and belt can be so severe, that material and dust escapes. Material spillage at transfer points needs to be removed and regular maintenance of belt skirting and transfer points is necessary.”
With the AirScrape dust-free and contact-free side sealing system for belt conveyors, there is no skirt contact and therefore no belt wear or damage. Motor power requirements are reduced as there is no belt-skirt friction and because there is continuous skirting with no gaps, product loss is minimal. Studies show, that even three years after installation and with continuous use in harsh conditions, the AirScrape system hardly shows any signs of wear. Operational costs are also reduced because there is no need for spillage collection, regular maintenance or replacement parts.
The system is available in pairs of left and right hand 2 m inter-connectable pieces, to form any required length and is available in three different base widths Âbetween 100 and 55 mm, to suit various belt widths and chute sizes. For flexibility on site, this system is completely extendable.
AirScrape is fitted using spacers, floating the blades just above the belt and is attached to the outside of the chute by utilising existing skirt clamps or a simple bolt and nut system. It is longitudinally adjustable to follow the contours of conveyor belt rollers and the belt trough angle.
This durable system consists of non-flammable and anti-static Polyurethane materials and blades made from Hardox/Stainless Steel. FDA-approved materials are also available for specific conveyor handling applications.
The system – designed and manufactured in Germany by ScrapeTec to the highest quality standards – is available from BLTWORLD throughout Africa and the Indian Ocean Islands. From Grupo-ISC throughout South America and from Scrapetec-Trading for the rest of the world. Scrapetec’s team provides an assessment and solutions service for planning and implementing each project. The correct installation of suitable equipment, ensures cost efficiency, optimum performance and safety, reduced risk of breakdown and extended service life of the conveyor system.
Anyone who, like Wilfried Dünnwald, looks back on many years of working as a miner in a managerial position knows the potential problems at transfer points of conveyor systems first-hand. It makes no difference in which industry the continuous conveyor technology transports bulk materials. It also makes no difference whether it works underground or open pit. Spillages or dust emissions are a nuisance for all industries. In order to be able to contain both of these problems permanently and at the same time without an exponential increase of the maintenance efforts for the skirtings of the transfers used for this purpose, Dünnwald brooded intensively over various technical principles. This basic self-study of the options included a strict exclusion procedure. What would have been the point of developing a further, basically similar technical solution to the ones already in place? The inventor’s own specifications were therefore also concerned with eliminating the well-known unfavorable side effects of existing systems. In order to break new ground in terms of wear and tear, maintenance-free operation and service life, only a contact-free method was ultimately considered and the Venturi principle came into focus. Based on this approach, numerous trials followed that proved increasingly promising in the course of the test runs and were additionally fueled by a corresponding customer order. The prototype of the now patented AirScrape was thus born in 2012 (Figure 2), laying the foundation for successful series production. This initial success encouraged Dünnwald to take production into his own hands and thus he founded ScrapeTec Trading GmbH in Kamp-Lintfort/Germany in 2015 (Figure 1).
Fig. 2. AirScrape operating principle: The contact-free design guarantees dust-free operation without the risk of belt wear and tear as with classic skirtings. // Bild 2. Wirkprinzip AirScrape: Durch den berĂĽhrungslosen Aufbau ist Staubfreiheit garantiert, ohne dass BandverschleiĂź droht wie bei klassischen Seitenabdichtungen. Photo/Foto: ScrapeTec
According to the current state, a user-relevant undertaking. Meanwhile about 1,000 belt transfers worldwide are protected by ScrapeTec solutions. “One of the first series production models of the AirScrape has been in daily use in a dolomite plant since 2013 and still performs its task reliably,” confirms the developer with justified pride. Also products that later followed the AirScrape under the names of DustScrape and TailScrape have always emerged from the specific needs that became apparent to the developing experts during on-site installations or were formulated by customers.
“It is exciting to always be able to find a suitable solution. In the meantime, we have found that transfer points offer more positive potential for this than was previously thought. Of course, I am primarily interested in the technical side. But now our products are also convincing those responsible for controlling and experts for occupational safety and health. This motivates the entire workforce and makes them happy,” says DĂĽnnwald, who likes to share the success of his company’s innovations.
How intensively the aspects of occupational safety, health protection, efficiency, cost reduction, environmental protection, energy saving – in short: sustainability – are linked to the use of an AirScrape system, is also regularly noted by ScrapeTec sales manager, Thorsten Koth. His current impression: “The AirScrape and its current product siblings have developed solid self-propelling tendencies and are in demand internationally. Our participation in relevant trade fairs has significantly increased the awareness of our products internationally. This offensive approach has also helped us to stabilize the ScrapeTec presence through newly acquired local partners.”
In addition, there is a lot of positive feedback from users: “All of them confirm how quickly the implementation pays off – if the operator does not shy away from the initially somewhat higher investment costs. The reward follows immediately and consists in working with a reliable, virtually wear-free system, actually no dust at transfers, better working conditions for the workforce, and less wear and tear on the belt, rollers and the entire system. Added to this is a plus in energy efficiency. If you want to get an idea of how the AirScrape works without going on a journey, you can easily find illustrative application videos on YouTube.”
With the flare-up of the corona restrictions, ScrapeTec has also accelerated its previously planned remote work. This segment offers, e. g., webinars or video conferences, in which problem cases can be presented on site with a camera and discussed with ScrapeTec’s experts. This saves time and costs in the run-up to the implementation, without compromising the real objective of a successful installation.
The references of ScrapeTec include numerous medium-sized companies as well as names such as RWE, K+S, Thyssen-Krupp or Saint Gobain. The AirScrape is now used worldwide at belt transfer points, proving its efficiency even under difficult climate conditions.
