Tenova TAKRAF

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

For further information, visit: www.takraf.com

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.

Further information:
TAKRAF GmbH
www.takraf.com

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.

Further information:
TAKRAF GmbH
www.takraf.com

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.

Further information:
TAKRAF GmbH
www.takraf.com

Further to the company’s innovative and reliable equipment for mining, bulk material handling and minerals processing, TAKRAF GmbH, Leipzig/Germany, is increasingly distinguishing itself as a complete service provider across the entire value chain. At bauma 2019 from 8th to 14th April 2019 in Munich/Germany, visitors will, for the first time, be able to have a complete overview of the company’s entire service portfolio, which ranges from project development services to technical studies on comminution and minerals processing, innovative fabrication solutions, various technical services and comprehensive after-sales support.

With a view to further developing their capabilities within the market of the comminution industry, TAKRAF continues to develop their range of roller presses, with a scale model of a High-Pressure Grinding Roll (HPGR) on display at the booth (Figure 1). Two of these machines are currently being manufactured at the company’s specialized fabrication facility in Lauchhammer. These machines can each handle more than 1,000 t/h of cement clinker, with each machine incorporating rolls with a diameter of 1,800 mm and a weight of more than 50 t per roller. In order to meet the challenging longevity requirements of such a machine, each roll surface is protected from wear by weld hardfacing for cement applications, and with tungsten carbide inserts for ore processing.

With the integration of the well-known DELKOR and Tenova Advanced Technologies – formerly Bateman Advanced Technologies – brand of products into TAKRAF as specialized product lines, the company’s portfolio for the minerals processing and beneficiation sectors has been considerably enhanced. At bauma, visitors will be able to focus upon the company’s capabilities in minerals processing, including Solvent Extraction (SX) and lithium recovery; as well as flotation, thickening, filtration and Dry Stack Tailings (DST).

Technical studies, which compare the techno-economic aspects of different system or equipment layouts are an intrinsic part of every investment process. The quality of the study strongly depends on the experience of the study team and the level of customer involvement. Based upon a common understanding of the weighting of all such decision criteria, the transfer of technical and operational experience and expertise, even beyond the own portfolio, is a key driver in enabling the customer to make a competent decision regarding the optimal solution for the specific conditions of their particular mine. More and more customers appreciate the added value provided by the studies as part of the engineering service portfolio, and for this reason, the company has decided to restructure and tailor their services even better in order to best meet customer requirements. TAKRAF’s Mining Technology Centre will be present and on hand to present the myriad of possibilities and benefits of innovative study approaches to demonstrate they are pursuing this strategy together with their customers.

In order to provide additional benefits and services to the company’s customers based on new digital technologies, several R&D projects in the field of the Industrial Internet of Things (IIoT) have also been advanced. In an attempt to find the most suitable technology which results in the greatest possible benefit for the customer, first pilot machines were equipped with remote data collection and evaluation systems. Utilizing a combination of edge computing and a proprietary azure-based platform established by Tenova, TAKRAF is able to develop applications that provide valuable insights of the company’s machines through modern and intuitive interfaces across any remote location. First results evince that this information can greatly assist in reducing downtime by identifying problems before they escalate into major issues and optimizing machine design, operation and performance.

Implementation of more advanced analytics and machine learning strategies are currently on the R&D agenda. In addition, remote support solutions can also be offered. This enables a remote experts-team to provide on-site assistance to the local commissioning or maintenance personnel using smart glasses and an appropriate software tool. This is a great solution for reducing reaction times and as a side effect for reducing or even avoiding costs for expensive and time-consuming trips to the destination area.

Visit TAKRAF at bauma 2019, hall C2, booth 349.

Further information:
TAKRAF GmbH
www.takraf.com

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.

Further information:
TAKRAF GmbH
www.takraf.com

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

With headquarters in Leipzig/Germany, TAKRAF is a leading global solutions provider in the mining, bulk material handling and minerals processing industries. The company is also an important manufacturer of high-end components such as belt pulleys and boasts a strong reputation in this area.

A contract covering the supply of an approximately 13 km long belt conveyor system was recently awarded by a globally renowned Chilean mining company to TAKRAF. This belt conveyor system will be installed in a copper mine in northern Chile. The scope of work includes, among others, the design, fabrication and supply of 39 belt pulleys specifically developed for this project. All pulleys are being fabricated at the TAKRAF workshop in Lauchhammer/Germany.

TAKRAF’s position as a leading global supplier in the engineering and fabrication of belt pulleys enabled it to meet the stringent requirements of supplying highly-stressed drive and return belt pulleys with a maximum diameter of 2.8 m and single weights of up to 60 t. Many of these pulleys will drive and handle the strongest steel-cord belt ever employed globally. The various challenges associated with such a project have been overcome by a dedicated team of highly skilled and experienced engineers and workers.

This extraordinary belt conveyor system, proudly supplied by TAKRAF with belt pulleys designed and made in Germany, will represent a major pillar of Chilean copper production for many years to come.

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