In a key project award, TAKRAF Group (‘TAKRAF’) is supplying seven DELKOR High-Density Thickeners and shear thinning technology for a new copper tailings facility for the National Copper Corporation of Chile (‘Codelco’), the world’s largest copper producer.
Known as the Talabre Thickened Tailings Project (Proyecto Relaves Espesados Talabre or PRET), the supply of DELKOR equipment represents a long-term solution for the disposal of copper tailings from Codelco’s North operations into what will be the largest thickened tailings project in the world.
Cose-up of the seven DELKOR Thickeners in the layout from the initial request phase of the Talabre Thickened Tailings Project (PRET) in 2023. Source: TAKRAF
Currently, copper tailings from Codelco’s Ministro Hales and Chuquicamata operations are sent to the existing Talabre tailings dam. While the dam’s lifespan has been extended over time through raising its perimeter walls, the dam is reaching the end of its useful life. Projected production levels require that PRET commences operation during the first half of 2027 for the miner to continue to effectively manage and improve tailings storage, while also increasing the recovery of water and reducing emissions of particulate material.
The contract was signed in 4Q 2024, with the project scope covering engineering, supply, technical assistance on site and spares for:
Seven 60 m diameter DELKOR High-Density Thickeners with on-ground tanks and 14 MNm MOT (Maximum Operating Torque) drives. These are some of the highest torque thickeners ever supplied by DELKOR who are known globally for their strong dewatering capabilities.
A multitude of DELKOR Shear Thinning Systems and ancillaries.
A DELKOR High-Density Thickener installed in Peru with a 60 m diameter, similar to the equipment being supplied for Talabre. Photo: TAKRAF
Located in the Antofagasta Region of Chile’s El Loa province, PRET is divided into two phases. The current project comprises the first phase to treat tailings coming from Ministro Hales and Chuquicamata, while the second phase will involve supply of further equipment catering to the additional management of tailings from Codelco’s Radomiro Tomic operations.
Dewatering of the tailings via the DELKOR Thickeners will result in a significant amount of water being reclaimed and directly reintroduced into the process, rather than being sent to a water treatment plant. Besides significantly reducing fresh water intake, the high water recovery of each thickener will allow operations to continue at all Codelco North operations. These operations would otherwise have faced severe challenges in ensuring the necessary water supply for their concentrator plants.
3D rendering of the DELKOR Thickener technology to be supplied to Codelco. Source: TAKRAF
“We are proud to continue our strong partnership with Codelco, supporting its commitment to environmental sustainability and operational safety. Our DELKOR High-Density Thickener is particularly suited to such applications where high water recovery is required. Through efficient and reliable water and tailings management solutions, we are able to assist our clients in meeting their goals while contributing to safer and more sustainable mining practices,” states Andres Costa, Managing Director of TAKRAF Chile and Peru.
TAKRAF Group CEO Thomas Jabs adds: “This project award reaffirms TAKRAF Group’s DELKOR brand as a global front runner and expert in dewatering solutions. Our DELKOR Thickener technology, together with other DELKOR dewatering technologies, play a crucial role in enabling operations to recover and recycle water, reduce their tailings footprint, and enhance process efficiency. These solutions not only address the challenges of water scarcity in regions like Chile but also contribute to safer and more responsible operations.”
From left to right: TAKRAF Primary Crushing Station and TAKRAF Discharge Conveyor to transport the crushed material to a TAKRAF Transfer Silo equipped with a belt feeder.
TAKRAF Group (‘TAKRAF’) is pleased to announce the award to engineer and supply the conveying system (CV-8001, CV-8002 and CV-8003) for Minera Collahuasi’s Ujina growth project in Chile.
The main objective of the Ujina growth project is to increase the capacity of the concentrator plant.
TAKRAF’s scope of supply: Conveyor system (CV-8001, CV-8002, CV-8003) to connect an existing, relocated crushing station to an existing conveyor system.
The Collahuasi mine is located at an impressive elevation of 4,535 m above sea level and has been in operation since 2003. It is one of the largest copper producers in the world, one of the largest copper deposits globally.
TAKRAF’s scope of supply for this brownfield project comprises the design and supply of three advanced conveyors This system will seamlessly connect a relocated crushing station to the mine’s existing conveyor network, ensuring efficient material handling under challenging operational conditions.
“We are particularly proud and would like to highlight the client’s continued interest in TAKRAF equipment, 20 years after the initial supply. This is a testament to the quality and excellence of our colleagues in designing and delivering exceptional equipment that ensures reliable operation, a fundamental requirement for any mining equipment.”, says Andres Costa, Managing Director of TAKRAF Chile and Peru.
TAKRAF extends its gratitude to the client for their trust and to its teams in Germany and Chile for their exceptional collaboration and technical expertise. This achievement reaffirms TAKRAF’s position as a leading provider of innovative solutions in mining and material handling.
First sustainability report voluntarily complies with the European Union’s (EUs) ESG reporting standard
TAKRAF Group’s ESG performance helps clients and partners reduce emissions, water use and waste, all while maintaining high safety standards
TAKRAF Group conducted double materiality analysis in consultation with both internal and external stakeholders
TAKRAF Group is presenting its first Sustainability Report and as such already complies with the EU’s European Sustainability Reporting Standards (ESRS) according to the Corporate Sustainability Reporting Directive (CSRD)
Leipzig (Germany), 3 October 2024: In this first Sustainability Report, TAKRAF Group reports on the impact of its operations, products and services on Greenhouse Gas (GHG) emissions, pollution, water and resource use, circular economy and waste. Furthermore, TAKRAF Group presents policies and actions regarding social responsibilities, governance and compliance. TAKRAF Group’s CEO, Thomas Jabs, points out that, “We prioritize helping our clients tackle sustainability challenges by offering energy-efficient solutions that reduce emissions, water use and waste, all while maintaining high safety standards. Our aim is to deliver solutions that add long-term value and help clients meet evolving environmental expectations.”
EU compliant reporting as an opportunity
In publishing its Sustainability Report for fiscal year 2023, TAKRAF Group has resulted in being one of the frontrunning companies in Europe to report according to the European Sustainability Reporting Standard (ESRS) which is the new standard of the EU’s Corporate Sustainability Reporting Directive (CSRD). “Sustainability is not merely a regulatory obligation. It’s a core element of our corporate strategy. We recognize that the industry in which we operate increasingly, and correctly, values sustainable solutions and transparent reporting. This is why we view the early adoption of the EU’s reporting regulations as an opportunity,” commented Thomas Jabs
The report is based on a double materiality analysis, i.e. an investigation of both, impact and financial materiality of environmental, social and governance topics. In conducting this analysis, TAKRAF Group engaged across its global internal and external stakeholder base. According to Thomas Jabs, this underlines that, “Our sustainability report is designed to reflect the expectations and feedback of our key stakeholders, including clients, employees, suppliers, and owner. By actively engaging with these groups, we ensure that our initiatives are in line with their priorities.”
TAKRAF Group’s reporting strategy combines methodological precision with readability
An EU compliant reporting scheme provides the basis for systematic strategic measures and communication on the most important ethical issues of our time. As such, TAKRAF Group has two reporting documents which address different readers:
The “Sustainability Report”, which is both easily accessible and informative, provides readers with a quick overview of TAKRAF Group’s ESG performance without having to deal with methodological aspects.
A “Technical Report”, compliant with EU’s ESRS, presents all the information on TAKRAF Group’s ESG performance and allows readers to develop a comprehensive understanding of data and methodology. Available upon request via info@takraf.com.
TAKRAF Group will further enhance ESG reporting and strategic ESG measures
TAKRAF Group boasts a long and esteemed history as an engineering company at the foundation of modern society’s value chains. “This commitment to sustainability is deeply rooted in our history. Since our history dates back almost three centuries, we reflect on how our products and services have consistently addressed the fundamental challenges of each era. Our long-standing trust in the power of technology, combined with our expertise as engineers, has positioned us as a trusted partner for clients worldwide,” reflects Thomas Jabs. Looking ahead, TAKRAF Group is committed to enhancing ESG reporting and developing strategic sustainability measures over the next three to five years. “As an engineering company, we are adept at designing innovative solutions and achieving exceptional performance. With the same dedication, we will continue to support our clients and employees while strengthening our governance,” concludes Thomas Jabs.
A new lead to boost the Group’s market position in times of important changes for the sector.
TAKRAF Group, a leading global provider of innovative technological solutions to the mining and associated industries, is pleased to announce today’s appointment of Thomas Jabs as Chief Executive Officer (CEO).
Jabs is a skilled leader with over 20 years of experience in the mining and plant engineering business in various executive and managerial positions. Graduated in Mechanical Engineering at the University of Aachen in 1998, Jabs currently lives in Cologne (Germany) and will move to Leipzig where TAKRAF Group has its headquarters.
“Thomas is the right person for TAKRAF,” said Roberto Pancaldi, CEO of the Tenova Group of which TAKRAF is part. “Thomas’s extensive background and business development skills will help TAKRAF strengthen its leadership position in the market. We are confident that he will be a force in developing and driving the Group forward in a very exciting but also challenging time.”
“I am very thrilled to be joining TAKRAF Group,” said Jabs. “I believe it is a very stimulating moment in the evolving mining environment, and the Group has a solid heritage and a great potential that uniquely position it. I am certainly looking forward to developing the company further with a clear ambition to help our customers reach their goals and to impact the future of mining positively”.
Implementing a Dry Stack Tailings (DST) solution provides a safe and sustainable alternative to the storage of tailings in impoundments.
The recent commissioning of a Dry Stack Tailings (DST) system supplied by TAKRAF to a Brazilian mine highlights the advanced expertise and unique positioning of the company to offer a complete end-to-end solution for safe and environmentally friendly mine waste management.
A “typical” flowsheet showing an example of TAKRAF’s complete DST solution. Source: TAKRAF
While the dry stacking concept is not new, with references as early as 1909 in Australia, technological advances have made DST an increasingly important alternative to conventional methods for handling mine waste, enabling mining companies to significantly decrease their risk profile.
Currently, the most widely utilized method of disposing tailings (waste material from the mineral extraction process) is to pump the tailings slurry to a dedicated impoundment area (pond or dam) to allow sedimentation to occur and solids to settle out. Part of the water is then recovered and re-used in the process. However, the risks and challenges associated with this method, combined with evolving mining conditions, mean that the safe and effective handling and deposit of tailings, whilst also considering the environment, is of ever-greater importance. Challenges include the considerable space requirement when storing tailings in impoundments, while the catastrophic tailings dam failures, which have occurred, resulting in significant loss of life and environmental damage, are a stark reminder of the risks.
Exacerbating the situation are current mining conditions, which utilize advanced mineral processing technologies to allow lower grade ores to be processed. This results in a much larger quantity of tailings that need to be safely stored. This ever-increasing tonnage of generated tailings makes a conventional deposit in dams an increasingly significant burden curtailing the expansion and development of mine operations and further highlights the potential of DST as a viable and beneficial alternative.
Advantages of DST
With DST, the moisture content in the tailings is reduced by a mechanized and controlled process to the point that it can be safely transported, deposited, and stacked as solid cake-form tailings. This yields several advantages over other surface-tailings storage options, including:
Significant safety improvement with the risk of catastrophic dam failure and tailings run-out being eliminated.
Transformation of tailings into a stable landform, and facilitation of rehabilitation and eventual closure.
Smaller tailings footprint and can be employed in undulating or steep terrain.
Suitability to areas of high seismic activity and areas where there is limited construction material to develop a conventional retention impoundment.
Reduced requirements for make-up water in plants, principally achieved by recycling process water, and near elimination of water losses through seepage and/or evaporation.
As tailings processing is complex, a detailed understanding of and expertise in the different steps specific to the commodity and project location are required. All equipment needs to be designed and/or adapted to specific project requirements and to be integrated seamlessly into the overall system. As a result, TAKRAF adopts a comprehensive and holistic approach to the design of its DST systems, combining its proven expertise in dewatering (DELKOR) and materials handling (TAKRAF) with a dedicated team of mining, materials handling, and processing specialists. This two-fold approach – bottom-up, equipment supply, and top-down, planning a long-term sustainable system – enables TAKRAF to develop solutions that best suit a client’s specific requirements, as well providing the client with a single point of responsibility during implementation. This approach has resulted in clients not only procuring equipment for tailings treatment, but also in contracting TAKRAF to carry out conceptual studies and economic trade-offs for DST systems. All this culminated in a recent DST system order being placed in January 2019.
DST system designed for Brazilian Mining Company
The order, placed by Mineração Usiminas, one of the Usiminas companies, and one of the largest steel producers in the Americas, comprised basic and detailed engineering, manufacturing, supply, transportation, and site assembly supervision of equipment to process iron ore tailings.
DST system under construction for the safe and effective handling of iron ore process tailings recently supplied by TAKRAF Brazil to Mineração Usiminas. Source: TAKRAF
The system is designed as a fully integrated dewatering process via thickening and filtration and includes the following main equipment:
4 x DELKOR filter press overhead beam (FP OH): 2 m x 2 m plates, each 170 t/h (nominal) and 187 t/h (design), capacity for 215 chambers
4 x compressors with tanks (process and instrument air)
4 x TAKRAF belt feeders: 2.0 m width, 31 m length with transfer chutes
Mineração Usiminas implemented the DST system to enable the filtering and stacking of tailings as the deposit area of the existing tailings dam reached full capacity. The process dewaters the tailings slurry in a single stream – a two-stage process using a DELKOR high-rate thickener followed by the filtration of thickener underflow using DELKOR overhead filter presses. The next process step allows further water recovery through the filter press, designed to achieve a moisture content level of about 14% (dry basis). Particular attention has been given to the redressing of the slurry using reagents to improve maximum recovery. The result is a dry filter cake that can be effectively handled and deposited.
In line with TAKRAF’s approach to supply site-specific solutions, the tailings material was extensively tested prior to the selection of the equipment. For example, the DELKOR filter presses, designed with a collaboration partner as an overhead beam type, are best suited for the operational conditions. The design of such machines enables them to process large volumes of material, yet are robust and maintenance-friendly, since they provide easy access to the filter plates and filter cloths.
“Sustainable water management, together with safety, are increasingly important topics for mining operations and all stakeholders around the world; especially in areas where water conservation is critical and/or tailings failure risks are significant as has unfortunately been the case in Brazil. The Mineração Usiminas project is testimony that implementing a full DST solution, in line with the overall mine development plan, is the most environmentally-friendly and beneficial approach for all stakeholders,” noted Thiago Machado, Head of DELKOR products at TAKRAF Brazil.
Buoyed by recent success, TAKRAF Group is ready to join MINExpo INTERNATIONAL 2021 eager to ask one question – what’s next for the global mining industry? Located at booth 349 in the North Hall, TAKRAF Group will host its engineering and service experts from across the continent, ready to engage with attendees regarding challenges faced by the modern mining sector, as renewed interest spurns investment in the Americas and elsewhere.
The Group has three major projects ongoing or recently concluded in the Americas – two in the US and one in Mexico. Each project, TAKRAF says, leverages the Group’s global expertise in engineering solutions for greenfield and brownfield developments, as well as in providing design, design/supply and turnkey execution strategies.
In the US, and despite the constraints of COVID-19, TAKRAF designed and supplied a materials handling system for a greenfield Hot-Briquetted Iron (HBI) plant, which commenced production in 4Q 2020. A second, also US-based, project concerned the development of the materials handling infrastructure required to relocate a semi-mobile in-pit crusher for a large copper mine. “The scope of this recently commissioned fast-tracked project included the design of a new belt feeder, two new overland conveyors that joined the repositioned crushing station with the existing conveyor system, and supply of a maintenance cart,” explained Eric Jackson, Director of Sales & Business Development. It is the third in a series of relocations that the Group has provided the same client, together with various other support, over the past two decades. Lastly, notwithstanding further COVID-related challenges, TAKRAF is in the process of providing a turnkey solution to a customer in Mexico involving a 6,000 t/h rail-mounted stacker and disassembly/removal of the old machine.
These and various other global projects, such as gearless drives at Chuquicamata in Chile, a large in-pit crushing and conveying (IPCC) installation in Russia, a large material handling project in Canada, wagon unloading station and materials handling system in Guinea, a 19 kilometer overland conveyor system for Utkal in India, and a large integrated stockyard handling and shiploading system for a major Russian port, will be presented during MINExpo, alongside technical innovations such as TAKRAF’s “XTREME class” sizers. For more information, visit TAKRAF Group at MINExpo 2021 in Las Vegas from 13-15 Sept. 2021, booth 349 in the North Hall.
What: MINExpo 2021 When: September 13-15, 2021 Where: Las Vegas Convention Center, North Hall, booth 349 in Las Vegas, Nevada, USA
Maximizing the sustainable recovery of minerals has become a critical success factor, at a time when the efficient recovery from less rich ores, aging or secondary deposits is one of the mining industry’s key challenges. TAKRAF Group, Leipzig/Germany, with its well-known DELKOR brand for liquid/solid separation and beneficiation equipment, has developed new generation BQR flotation cells with the proprietary MAXGen mechanism for best-in-class metallurgical performance (Figure 1).
The exceptional MAXGen mechanism is the result of extensive research and development from bench scale tests, 3D prototyping, pilot scale studies and plant scale trials. MAXGen stands for superior recoveries with higher mineral grade, along with faster flotation kinetics by generating favorable bubble size distribution and energy efficient hydrodynamics. The distinctive configuration of rotor and stator enables the rotor to operate at a lower tip speed. Hence, it reduces operational cost with lower power consumption and wear.
The new DELKOR BQR MAXGen flotation cell also boasts more eloquent features addressing many practical challenges when improving installation, maintenance and operation of flotation circuits, particularly in existing concentrators. The “bypass ready tank design” of DELKOR BQR MAXGen, e. g., allows the installation and upgrade with cell bypass systems at any stage of the project, without compromising the original layout and without any modification to the tank shell. This flexibility makes adjustments faster and less costly, enabling operators to maintain the best flotation bank set up over time.
The new DELKOR BQR MAXGen flotation cell also incorporates deeper launders with higher slope to assist the froth to evacuate quickly. The launders can also be customized with various options of external, internal and radial launders to suit specific froth transport parameters based on the application.
The former Mining Division of Tenova, commonly known as TAKRAF GmbH, Leipzig/Germany, with its integrated product brand, DELKOR, has revised its branding as of 5th October 2020 to now operate as TAKRAF Group. The revised branding underlines the Group’s core strengths and value-adding proposition towards clients and partners within the mining and adjacent industries (Figure 1).
TAKRAF is recognized as the world’s leading technology brand when it comes to handling high capacity run-of-mine and bulk material. Its portfolio ranges from overburden removal to raw material extraction, comminution, conveying, loading/unloading, processing, homogenizing, blending, storage, and final loading for onward shipment.
The DELKOR brand is associated with liquid/solid separation and beneficiation equipment with thousands of successful installations worldwide. DELKOR products are specifically designed for the rigors of the mining industry, combining high performance technology features with proven robust designs.
TAKRAF Group remains a Tenova company, known and respected globally as a partner for innovative, reliable, and sustainable solutions in the metals and mining industries.
TAKRAF GmbH, Leipzig/Germany, is a highly specialized supplier of machines and services in the fields of mining, materials handling and minerals processing. As such, TAKRAF boast a large base of installed machines that daily generate valuable data from which we can gain information regarding optimization of design, operation and maintenance or even troubleshooting.
Leveraging this opportunity, TAKRAF rolled out an initiative for the collection of operational data for selected representative machines and/or key components. Based upon current IIoT technologies available today, TAKRAF equipped a select sample of machines with remote data logging systems as a part of its aforementioned R&D initiatives. One of the first successfully integrated systems is running in one of TAKRAF’s high-capacity spreader and tripper car for a large overburden-handling project in South East Asia. This system was designed and is based upon hardware and software components supplied by iba AG, a specialist for data logging and analysis. A machine connector reads defined data from the Profibus DP of the machine control system without jeopardizing its security and/or integrity and writes those to the iba PDA server. On this server, the data is locally stored and analyzed, e. g., for automatically generated reports. Recorded data are then sent to TAKRAF’s head office simultaneously or in batches.
A few further outcomes from TAKRAF’s R&D activities include remote support solutions employing “smart glasses” (Figure 1). Such tools are relatively easy to implement and already quite readily available. With these glasses, TAKRAF is able to connect experts in an office with its commissioning engineers or its clients’ maintenance staff on site in order to solve specific problems quickly and effectively, avoiding long trips and associated travel costs.
Another “smart tool” TAKRAF successfully presented at the 2019 BAUMA mining exhibition in Munich/Germany is based on Schneider Electric’s “Augmented Operator Advisor”. This software tool, which runs on a tablet, is able to determine its positioning in the field based upon image recognition of the various parts around the user. Based upon this recognition, various “points of interest” can be defined together with context sensitive information such as manuals and maintenance procedures – live data can also be made available to the user.
TAKRAF has recognized the enormous benefits that IIoT technologies can provide its customers, together with the improvement of its own internal processes. As a result, IIoT is fully supported throughout its organization and plays an increasing role across all the product lines.
TAKRAF GmbH, Leipzig/Germany, announces the receipt of an important project award for the supply of two High-Pressure Grinding Rolls (HPGRs) for a cement plant in Turkey. The company’s HPGR machines (Figure 1) have been designed from the outset with maintainability in mind. A clear target to achieve this goal is the reduction of downtime, which includes integrated maintenance tools and a focus on the changing of wear parts. Furthermore, the machines boast a load optimized frame structure, which ensures the effective operability under varying load conditions.
In this application, each HPGR incorporates rolls with a diameter of 1,800 mm, a width of 1,600 mm and a weight of more than 50 t. Two variable frequency drives with a combined power output of around 3,000 kW provide the power to process more than 1,000 t/h.
Additionally, each roll’s surface is protected from wear by weld-hardfacing. The company recently installed a specialized welding machine for this very purpose. This specialized machine is able to guarantee constant quality throughout the entire hardfacing process and ensures that the hardened rolls are able to meet the demands placed upon them.
Engineering will be conducted by a joint team based at TAKRAF’s production facilities in Lauchhammer/Germany together with colleagues from the Cologne office. The machines will be manufactured in Lauchhammer, with delivery scheduled in the first half of 2019.
