Voith Turbo GmbH & Co. KG

Voith Hydro,Heidenheim/Germany, a leading global supplier of hydropower and pumped storage equipment, and Swedish company Mine Storage, a specialist in the field of underground pumped storage concepts, announce a development partnership to become the forerunners in a new market for underground pumped storage – offering so-called mine storages (Figure 1).

The Paris Climate Agreement has made clear that to prevent a global climate collapse, global warming needs to be limited to maximum 1.5 °C. To achieve this, it is necessary to focus on the use of clean, renewable and resource-conserving technologies in energy generation. Hence, there is a need for transition from fossil fuels to low-carbon and sustainable alternatives, a move that Voith Hydro and Mine Storage aim to help facilitate.

For the global phase-out of fossil fuels, large-scale electricity storage is needed. More than 90 % of energy storage today is provided by pumped storage hydropower, as it allows for quick response with incomparable flexibility to fluctuations in energy demand. This enables the integration of volatile renewable energy sources, such as wind or solar power, into the grid and stabilizes it. With the current stage of technology, it is the only possibility to store energy in an economically viable, large-scale way.

Mine Storage focuses on the rapidly emerging market for large-scale, fast-responding energy storage and plans to build sustainable pumped storage facilities in underground mines. These are called mine storages and can act as “batteries” that help balance the electric grid so that much more production from wind and solar energy can be added without creating a volatile electric grid that is prone to blackouts. There are more than 1 M abandoned mines in the world, and with mature, proven energy storage technology, mine storages can be a game changer for the environment.

Replicating traditional pumped storage with upper and lower reservoirs in a new setting, like underground mines, can truly accelerate the transition from brown to green energy. The mining environment, however, puts new demands on the technology, thus the challenge lies in combining industry-specific knowledge from different fields.

Voith Hydro has long been in the forefront of technology development and will take on these specific challenges. In collaboration with Mine Storage, the company is now engaged in the early project development at two specific sites in Sweden in order to develop the necessary technical solutions.

”We are committed to sustainable technologies and concepts for a decarbonized future. As Mine Storage has shown an innovative approach, impressive speed and competence in this field, we are delighted to now bring in our long-standing expertise in pumped storage technology in order to develop first projects together,” says Uwe Wehnhardt, President & CEO Voith Hydro.

“Mine storages can have a huge impact on global CO₂ emissions by enabling renewable energy production to scale. We do not have time to wait; we must act now,” says Thomas Johansson, CEO of Mine Storage. “Voith Hydro has shown a great flexibility and good understanding for the dynamics in early project development. Their approach and our shared vision of the global potential for mine storages make this partnership a valuable piece in our strategy to contribute to the phase-out of fossil fuels.” (Voith/Si.)

The global technology group Voith GmbH & Co. KGaA, Heidenheim/Germany, is planning a comprehensive package of measures for its Voith Turbo division in order to secure the competitiveness and sustainability of the division over the long term. The focus is on streamlining the production base in Germany. The aim is to create central, higher-performing locations where essential parts of production are bundled. The plan is to stop production in Sonthofen and Zschopau by the end of 2020.

“Voith Turbo is confronted by increasing competitive pressure and pressure on margins. At the same time, the need for investment is also constantly increasing in order to assert our position as a technology and innovation leader in the industries supplied by Voith Turbo. With the planned package of measures we want to make Voith Turbo more efficient and effective and thus secure the competitiveness and sustainability of the division over the long term”, said Uwe Knotzer, Chairman of the Executive Board of the Turbo Division.

More specifically the plans include changes in the production network, mainly in Germany. At the Sonthofen and Zschopau sites, where Voith currently manufactures products from the industry and mobility areas, it is not economically viable to continue production. It is therefore intended to stop production in both factories by the end of 2020. The corresponding capacities would be relocated to other existing locations of the division.

The concentration on fewer, but bigger and more distinguished locations would come with a moderate level of job losses in Germany. On balance, a total of around 230 jobs would be lost, and another nearly 370 positions would be relocated to other locations. By 2021 the package of measures should have a positive impact on earnings at Voith Turbo in the low two-digit million range.

Knotzer: “The division management of Voith Turbo is aware that the planned cuts at the affected locations are very painful. And we also recognise the responsibility we have as a company. This is why we want to implement the upcoming changes in close cooperation with the local employee representatives as fairly and as socially acceptable as possible. At the same time, we are firmly convinced that the planned measures are unavoidable in order to keep Voith Turbo on the road to success in the future in a fast changing environment.” (Voith/Si.)

Voith Turbo GmbH & Co. KG, Heidenheim/Germany, recently unveiled its new TurboBelt 500 TPXL fluid coupling at MINExpo in Las Vegas, USA (Figure 9). The fill-controlled coupling is the first model in the new TPXL family, which combines the advantages of the proven hydrodynamic drive principle with intelligent control technology. The integrated controller makes it possible to adapt the output torque of the coupling exactly to the startup parameters of the belt conveyor system. In addition, Voith’s engineers have been able to considerably reduce the dimensions of the new coupling, so that the TurboBelt 500 TPXL only requires half the volume of conventional coupling types whilst maintaining the same transmission force. In addition to the operational advantages, the new series of couplings also offers attractive procurement and operating costs.

Operation of the TurboBelt 500 TPXL is simple and user-friendly. After the required torque for the belt and the basic startup parameters have been transmitted, the coupling automatically calculates the optimum fill level in real time and fills or drains the working circuit accordingly. Equipped with a self learning function, it simultaneously stores all relevant operational data in order to align the control behavior optionally with the nominal value, depending on the respective load situation and on the basis of previous empirical values.

This TurboBelt 500 TPXL is plug-and-play design enabled. An integrated controller, an integrated pump and a new oil supply unit are part of the coupling concept. Thus the components are optimally matched to one another and pave the way for predictive, requirement-oriented and cost optimized maintenance of the coupling. The controller monitors the entire sensor system of the coupling and provides operationally relevant information, such as the condition of the oil filter. Even by remote access, if desired.

As a self-contained system, the coupling can be easily put into operation without long interruptions in production. In order to allow for the integration into new as well as existing drive trains, Voith offers a version with bearings on both sides for standalone use as well as a variant with bearings on the output side for direct motor connection.

Thanks to the hydrodynamic operating principle, power transmission via the TurboBelt 500 TPXL is wear-free and does not require a mechanical connection. New vanes with the XL profile double the power density of the coupling in comparison to conventional coupling types. This means that only half the volume is required to transmit the same force.

The hydrodynamic circuit of the coupling limits the torque in the driveline to a fixed, defined value which protects the belt and the drive components from damage due to overloading. This minimizes maintenance costs and increases the lifetime of the system. Motors can be run up to speed under no-load conditions and staggered in time using the fill control system. This minimizes the current peaks that always occur when motors are switched on and reduces the load placed on the power grid.

In parallel with the integrated controller unit, which controls the oil supply to the working circuit among other things, the TurboBelt 500 TPXL is also equipped with a fieldbus unit. With this, Voith lays the foundation for the mining of the future. Thanks to connected components over the entire extraction process, operators can profit from high conveyance performance and increased productivity as well as from increased work safety.

Within the Voith portfolio the TurboBelt TPXL fill-controlled coupling is complemented by components over the entire conveying process such as the intermediate drive TurboBelt TT Linear Booster Drive, storage loops, tension stations and slide and chute systems. Today, this already offers diverse possibilities for optimizing belt conveyor systems with respect to total cost of ownership and capital expenditures. Furthermore the wide product range opens a perspective for the future with regard to automation concepts and comprehensive condition monitoring.

Further information/Weitere Informationen:
Voith Turbo GmbH & Co. KG
www.voith.com

When crushing mined rock and materials, uncrushable objects constitute a severe risk for the production process as well as the installed equipment. In order to limit torque load without disrupting operation, Voith GmbH, Heidenheim/Germany, designed its SlipSet coupling to temporarily slip in the event of an overload situation and thus act as a shock absorber (Figure 9). The company’s recently developed Coupling Monitoring System (CMS 310) offers further benefits by providing real time status information as well as performance analyses; displayed in a particular web interface, on a HMI panel or integrated in an already existing supervision system.

When getting stuck in the crushing chamber or between the rollers, too hard materials or too huge pieces cause the system to stop running. As the motor and the momentum of the driveline still deliver torque, the resulting overload overheats the motor or leads to the collapse of the driveline. To avoid cost-intensive repair works or downtime, belt drives can be replaced with direct drives protected by an integrated torque limiting coupling.

Voith SlipSet couplings consist of a twin-walled hollow sleeve with friction generated by pressurized hydraulic oil. In case of a torque peak which exceeds the preset torque limit, it will instantly slip and protect the equipment from high stresses. If the blockage persists, the coupling slips until the rotational energy is completely absorbed and the drive can be stopped to enable the blockage to be cleared. On a scale of 1 to 20,000 kNm the trigger point for slipping can be set at 50 to 100 % of the maximum load. Due to its compact design, the SlipSet coupling is easily installed at the optimum position in the driveline. As it separates the input torque from the output torque of the driveline, the slipping feature of the SlipSet coupling paves the way for a detailed monitoring of the coupling and the occurring forces around.

In order to increase product intelligence and enable nonstop performance supervision, Voith developed the PLC based Coupling Monitoring System CMS 310. It is based on the calculation of the torque limiting coupling input and output rotational positions. The measurements are made by inductive sensors mounted on each side. If the coupling slips, there will be a pulse difference between the sensors. The difference in relative position is recorded and recalculated to a slip angle in real time.

Once a slip occurs, the CMS informs the operator about the incident via a web interface or an optional HMI panel for closed systems. Depending on the respective information, the operator can either adapt the power input, material feed or initiate a controlled shut down. This ensures the maximum output of the crusher since it helps the operator to align the motor power with the full capacity of the machine.

The used Profinet communication standard makes it easy to individually integrate relevant data from the Voith CMS into existing supervision systems. Thus, it requires no particular monitoring activities – still offering the possibility of accessing a history log for in-depth analyses, product settings as well as product information in the web interface provided by default.

As the Voith CMS also documents the number and length of slips of the SlipSet coupling, it proactively highlights the upcoming need for service. Therefore, coupling maintenance can be aligned with the overhaul of further components to not only prevent unplanned downtimes but also reduce planed standstills.

Further information/Weitere Informationen:
Voith Turbo GmbH & Co. KG
www.voith.com

Voith GmbH, Heidenheim/Germany, has installed a TT Drive on the H2 belt conveyor in the RAG´s Prosper-Haniel coal mine in Bottrop/Germany without interrupting operation and achieved a comprehensive solution with the subsequent installation of another TT Drive that resulted in sustained cost reduction for the mining company.

With the installation of the first TT Drive, Voith made it possible for the Prosper-Haniel mine to carry on using a heavily damaged steel cord belt (ST5000) until the next scheduled downtime and thus prevented an unplanned shutdown and corresponding production loss. During the next downtime, Voith installed a second TT Drive in the H2 belt conveyor. This allowed for a further reduction in belt tension forces and Prosper-Haniel has since then been able to operate the belt conveyor with a cost-saving textile belt (PVG2000/1). The H2 belt conveyor transports the mined coal over 1,270 m with a lift of 186 m vertical. Its operating speed amounts to 3.2 m/s with a capacity of 2,000 t/h.

The Voith TurboBelt TT Linear Booster Drive is a high-performance secondary drive (Figure 1) for belt conveyors. It extends the use of belts in existing systems and increases their available power. In new belt conveyor systems, it reduces the requirements on belt quality, leading to considerable cost savings.

Further information:
Voith Turbo GmbH & Co. KG
www.voith.com

Voith has taken over parts of conveying equipment specialist Hese, headquartered in Gelsenkirchen, Germany. Hese‘s current factory site in Gelsenkirchen is not part of the takeover. On 12th November 2014, the company filed for insolvency. The areas that have been taken over are to be incorporated into the Mining & Metals division of group division Voith Turbo.

Hese is known in the mining sector for developing the carrier belt-drive belt drive system (TT drive system). TT drive systems allow belt conveyor systems to be operated continuously over longer distances without the need for a different belt quality and with increased efficiency. Additional belt transfer points are not necessary, less dust is produced and the impact on the broken material is minimised.

TT drive systems are also currently one of Hese‘s best-selling mining conveying products, alongside conveyor belt drums (available in various diameters) and the retractable guide rail. They are fitted in the shaft and allow cages to pass through more quickly along the worked stratum. Hese has also made a name for itself in bulk materials conveying, offering both system components and complete systems.

The Mining & Metals division, into which those parts of Hese that have been taken over are to be incorporated, develops and produces products such as coupling technologies and drive systems. These products are used for conveying and transporting raw materials mined both underground and above ground. They provide international industry with important raw materials such as coal, copper, iron ore and nickel.

Voith Turbo, a group division of Voith GmbH, specialises in intelligent drive solutions and systems. Customers from industries such as the oil and gas, energy, mining, metalworking, marine engineering, rail and utility vehicle industries all use technologies developed by Voith Turbo.

Further information:
Voith Turbo GmbH & Co. KG
www.voith.de

Voith recently manufactured their 1,000th fluid coupling type TPKL. This coupling will go to the DaTong Coal Mining Group in China. The group has already made good experiences with Voith fluid couplings: Convinced by the good performance of hydrodynamic power transmission the decision for the drive line arrangement in the main belt conveyor of a new coal mine was also made in favor of Voith fluid couplings. In this specific case the mine will receive four fluid couplings type TPKL. The fill-controlled fluid couplings will be used in a 6.4 MW belt conveyor drive with demanding requirements. The 3,160 m (10,367 feet) long underground belt conveyor is driven by four 1,600 kW motors, with a planned capacity of 4,000 t per hour. The belt conveyor is designed for a demanding workload as it will transport coal uphill at a 14° angle.

Voith started the production of the TPKL coupling series in 1997. This fluid coupling type was especially developed for demanding belt conveyor applications in mining. The coupling type provides a torque limitation for a smooth start-up of the belt conveyor. It allows active load sharing with multi-motor drives. Thanks to its standstill cooling function it can handle difficult start-ups multiple times in succession. (Voith/Si)

Further information:
Voith Turbo GmbH & Co. KG