TAKRAF GmbH

With the mining industry mood picking up, the level of interest in In-Pit Crushing and Conveying (IPCC) solutions is again increasing, and the South-American market plays a key role in the industry. For this reason, International Mining Events held its 5th IPCC conference in Santiago/Chile, on 26th to 27th April 2018. Crushing & conveying experts from TAKRAF GmbH, Leipzig/Germany, had the opportunity to take part in the event and present the company’s know-how, expertise and solutions to over 120 participants, including potential clients and other relevant stakeholders (Figure 1).

As ore grades decline, waste rock to ore ratios increase and mines become progressively deeper – mining operations are facing greater challenges in ever-more complex scenarios. Despite various rationalization efforts, material transportation costs have increased significantly over the past decades and currently account for up to 60 % of overall mining costs. Thus, considerations and efforts to reduce overall mining costs, promise highest success when focusing on the development of more economic material transport methods. “The paper has the objective to develop a structured method for the determination of an appropriate IPCC system that incorporates the random behavior of system elements and their interaction”, affirmed Robert Ritter, TAKRAF Mine Planning Engineer, in his presentation. “This method is based upon a structured time usage model specific to IPCC systems supported by a stochastic simulation”.

A further paper, delivered by Walter Küng of TAKRAF USA, presented various semi-mobile IPCC systems, which found interest among many attendees. The topic represented viable, safe and decreased fossil fuel dependent alternatives in comparison to other material handling systems. The presentation elaborated on various configurations of fixed, semi-fixed, semi-mobile and fully mobile crushing station designs. It analyzed capital and operating costs for each and determined break-even scenarios, all based on high altitude South American conditions.

TAKRAF successfully demonstrated their in-depth knowledge and expertise by both scientifically determining the reliability and capacity of in-pit crushing systems, as well as highlighting the extensive experience in designing, supplying, constructing and commissioning of such systems in various parts of the world and under variable and extreme operating conditions. (TAKRAF/Si.)

Amidst the numerous five-star all-inclusive resorts in Playa del Carmen in Mexico, TAKRAF USA – part of the global mining, bulk material handling and minerals processing equipment supplier, Tenova TAKRAF – has erected and successfully commissioned a 6,000 t/h rail mounted shiploader at an important limestone mine’s port facility (Figure 1).

The client, a NYSE listed entity and amongst one of the largest producers of construction aggregates in the USA, is major supplier of limestone to North America, with the port typically loading around 20 Panamax (50 – 60k DWT) sized cargo ships per month. The new shiploader recently loaded the required three ships without incident, thereby successfully completing the performance requirement of the contract.

The shiploader was designed and pro-cured from TAKRAF’s Denver office with structural steel being fabricated in nearby Merida/Mexico. The new machine provides many improvements over the existing 30 year old machine including upgraded capacity, up-to-date VFD controls, improved redundancy, and numerous maintenance and safety enhancements.

“The TAKRAF team on site managed an unbelievable feat by removing the existing shiploader and preparing the new machine for operation in a mere three days – an incredible two days less than required by the contract”, said Tom Gramling, TAKRAF USA President. “This, together with the strong performance of our machine, resulted in the client expressing complete satisfaction with our service and how we operate. We strive to ensure that we work for the best interests of our clients and their operations.”

Further information/Weitere Informationen:
TAKRAF GmbH
www.takraf.com

TAKRAF GmbH, a Leipzig based company with a wealth of experience in development, design, fabrication, erection and commissioning of equipment and systems for the global mining and material handling industry, has secured a major contract for the turn key supply and installation of a bauxite handling plant in Guinea, West Africa. The contract value is approximately 100 m e. TAKRAF, with roots dating back to 1725 and with more than 1,000 employees worldwide, is affiliated to TENOVA spa, a technology based group of companies based in Italy and a leading integrated supplier of technology and turnkey industrial plants.

Guinea, situated on the west coast of Africa, boasts the world’s largest reserves in bauxite, a raw material utilized for the production of alumina, which is used in the smelting of aluminum, a metal important in the aviation industry, automobile fabrication, and many more durable goods manufacture.

Compagnie des Bauxites de Guinée (CBG), jointly owned by international mining houses and the State of Guinea, mines and exports bauxite for more than 50 years and has put in place an ambitious program to increase their export capacity, for which TAKRAF supplies equipment for the unloading of rail wagons and crushing and conveying of the bauxite (Figure 1). A major challenge is the brownfield character of the works, which means that the new supplies and modifications to the existing plant have to be carried out whilst the installation is in operation. Very limited plant downtime and difficult conditions for logistics are a further challenge.

TAKRAF is executing this contract in close cooperation with their subsidiaries in the USA, China and South Africa, whereas the project lead is based in Leipzig. The commissioning of the plant is scheduled for the 2nd half of 2018.

Further information/Weitere Informationen:
TAKRAF GmbH
www.takraf.com

With hundreds of complete systems, as well as individual machines, having been supplied to clients all over the world, Tenova TAKRAF is a key supplier of equipment and systems for open pit mining and bulk handling. The international company offers innovative technological solutions as well as process and commodity knowledge along various industry value chains. Recently, TAKRAF’s product portfolio has been enhanced with the addition of sizer equipment, which now enables the company to integrate its own crushing machines into complete mining solutions for its clients.

TAKRAF offers standardized primary and secondary sizers for various crushing applications. The primary sizer product range covers inlet sizes from 2.5 m to 4.0 m with a throughput of up to 10,000 t/h; whereas the secondary sizer range covers inlet sizes from 2.0 m to 4.0 m with a throughput of up to 3,500 t/h. Both sizer product ranges are suitable for the comminution of all material types, from standard to most challenging.

A key differentiating factor of TAKRAF’s sizers is the fact that special focus and attention was directed towards attributes such as ease of maintenance, reduced downtime and long equipment service life already during the sizer’s initial development. As a result, this sizers offer unparalleled levels of maintenance efficiency and service life. Some of the innovative solutions adopted include the quick and easy changing of crushing segments, as well as the use of advanced wear resistant materials such as hard-faced segments and tungsten picks. Other innovative solutions include an inching drive for roll maintenance, which increases safety significantly, a heavy duty drivetrain system; as well as adopting an efficient oil lubrication system with a view to greater environmental sustainability.

Rock fragmentation and abrasion are critical elements with regards to material characterization. As a result, TAKRAF boasts in-house test facilities in Germany where it is able to conduct material tests across a wide variety of conditions (Figure 1). Determination of material crushability and wear behavior can thus be analyzed by specialized test machines, the results of which can then be employed to assist in sizer selection. Furthermore customized wear predictions of the crushing tools can also be determined.

TAKRAF at the bauma: Hall C2, Booth 349

Further information/Weitere Informationen:
TAKRAF GmbH
www.takraf.com

In August 2014, Takraf GmbH received an order from Vattenfall Europe Mining AG for the supply and installation of the new cross-conveyor system for the F60 conveyor bridge in the open cast mine at Welzow-Süd/Brandenburg. The scope of services included the fabrication respectively conversion of hopper cars and chassis as well as the scrapping of system components which would no longer be used. The special challenge of the project was the tight schedule. Thanks to the commitment and the long-standing experience of all experts involved in Vattenfall and Takraf, the system could be delivered after ten months, as planned.

Production started immediately after the award of the contract, and the first parts arrived at the site after five months. In May 2015, the complete conveyor bridge was moved by about 10 m in order to couple the new cross-conveyor system to the bridge. Until end of June 2015, the cross-conveyor system had been further assembled.

All personnel involved in the project team in the fields of engineering, fabrication and site erection worked closely together, thus enabling the successful realisation of the contract within the pre-determined schedule, benefitting from the expertise developed over many years in complex reconstruction and modernization works, as e.g. changing the tension tie rods on the conveyor bridge in the Jänschwalde open cast mine. The cross-conveyor system was able to be completed in June 2015.

After three days of commissioning of the conveyor bridge complex by experts from Vattenfall, the conveyor bridge went back into mine service.

TAKRAF is already working on another project at Vattenfall, i. e. changing the large bogie and the roller table at the F60 conveyor bridge at open cast mine Nochten.

Further information:
www.takraf.com

Open pit mining and underground solutions provider, Tenova TAKRAF, has completed the supply and installation of a complete Bucket Wheel Excavator (BWE) system for Zhahanaoer Open Pit Mine in Inner Mongolia, China. The system, which features the largest Bucket Wheel Excavator-Conveyor-Spreader-combination of its kind in Asia, was inaugurated in late November 2014, attended by representatives of the client, CPI Mongdong Energy Group. The inauguration followed successful performance testing, which confirmed the efficiency and reliability of the entire system and exceeded the expectations of all parties.

The system consists of a large-scale Bucket Wheel Excavator SRs 2000 (rated capacity 6,600 m³/h) with loading unit, a 7,750 m long conveyor system consisting of five flights as well as a compact spreader with tripper car on rails. The Bucket Wheel Excavator reaches 30 m digging height, and although it has a service weight of about 3,300 t, it has a ground pressure much lower than that of a D11 Dozer. In order to properly handle peak capacities the conveyor system as well as the spreader have a design capacity of 7,900 m³/h. Those conveyors running along the excavator bench and along the waste dump are shiftable.

The project commenced in September 2009 with the Bucket Wheel Excavator, spreader and conveyor system awarded in three stages from 2009 to 2011. The complete turnkey project covered design, supply, transportation, on-site installation, commissioning and testing.

The project site is located approximately 700 km from Beijing in remote northern China, where the extreme climatic conditions see winter temperatures of down to -40 °C and summer temperatures of up to +40 °C.  Despite the highly challenging conditions, the project teams achieved a smooth erection and commissioning process, completing the project on schedule in early November 2014.

The project is regarded as an important milestone in the development of China’s mining industry, typified by a trend towards larger scale mines and mining equipment. It also provides a good example of successful German-Chinese-cooperation. For Tenova TAKRAF, the project continues its success with the supply of Bucket Wheel Excavators to China, and follows the delivery of two BWE systems to Yuanbaoshan in the 1990s.

Further Information:
TAKRAF GmbH