german mining

With the closure of many of

Germany’s mines over the last few

decades, the manufacturers that

were established on the back of this success

have had to evolve. To do so, they have

branched out from Germany and coal mining,

into other major mining centres, equipped with

new hard rock technologies.

Research and Markets’ Metals and Mining:

Germany Industry Guide report offers a

background to Germany’s metals and mining

industry. It includes five-year forecasts for

aluminium, coal, metals and mining and steel.

Highlights of the report include:

■ The German aluminium market generated

total revenues of $1.3 billion in 2007,

representing a compound annual growth

rate (CAGR) of 6.7% for the period

spanning 2003-2007

■ The German coal market generated total

revenues of $13.1 billion in 2007,

representing a CAGR of 6.9% for the period

spanning 2003-2007

■ The German metals and mining industry

generated total revenues of $57.6 billion in

2007, representing a CAGR of 7.8% for the

period spanning 2003-2007

■ The German steel market grew by 20.6% in

2007 to reach a value of $34.4 billion.

Beginning with all-important sampling for

exploration and other tasks, Bruker AXS’ new

simultaneous WDXRF spectrometer S8 LION

combines ease-of-use with analytical speed and

reliability for process and quality control. It is

designed and built for speed and accuracy and

can simultaneously measure up to 16 elements

with a precision of 0.05% (RSD) and time-to-

result of less than 60 seconds in raw materials

and industrial minerals. In designing the

spectrometer, applicable industry standards

such as ASTM C-114, were matched or

exceeded.

The company says the S8 LION is one of the

most compact high-performance simultaneous

WDXRF spectrometers in the market, allowing

simple integration into any laboratory and

process automation. It integrates Bruker’s

unique TouchControl™ and SampleCare™

features for extreme ease of use and reliability.

TouchControl enables simple and essentially

fail-safe operation via the integrated touch

screen, requiring virtually no user training.

Several languages for the user interface are

available, such as English, Spanish, Chinese,

Russian and Portuguese. SampleCare ensures

maximum uptime and availability with a tube-

above-sample setup protecting the S8 LION

against contamination. The ease of use with

TouchControl and SampleCare technology, as

well as the new, unique free-lime channel,

which integrates XRD capabilities into the XRF

spectrometer, makes the S8 LION an ideal tool

for precise, rapid and effective process and

quality control.

Going undergroundGermany has some big manufacturers for

underground machinery and one such is Paus,

which since its foundation around 40 years ago

has been focused on the transport of

explosives, especially ANFO. It also, of course,

makes LHDs, trucks and a wide range of utility

vehicles. The Paus Universa 50 carrier vehicle

allows the transport of up to 1.5 m3 of

explosives. By means of the hose pusher and a

dosing unit, especially developed for filling

blastholes, explosives can be placed in the

holes in a suitable and cost-effective way. The

telescopic working platform allows access to

heights up to 12 m. At the same time, the

vehicle carries all tools and necessary blasting

accessories, such as ignition systems and

cartridges.

The Universa 50 platform is available for

payloads from 4.5 to around 7 t. This machine

has, according to the company, proven its

reliability for years and consequently gained a

great reputation; the vehicle is equipped with

articulated steering and four-wheel drive and is

the basis for all possible underground transport

jobs.

In LHDs, GHH’s new drive concept, the

Efficient Drive System (EDS), has made a

significant impact on its newest machine: the

LF-10/11. The reduced dimensions, energy

efficiency, higher productivity and

Germangreatness

looks at some of the newestdevelopments coming out ofGermany, which includesadvances in LHDs, longwallshearers and screens

ThyssenKrupp’s solution for the Cöllolar coal mine

included a Truck Dump Station that can be fed by five

trucks simultaneously. Each station has two feed

hoppers and type DRS 950 x 2500 CS sizers

underneath that are fed directly by the dump trucks

GERMAN TECHNOLOGY

DECEMBER 2009 International Mining 33

ergonomically designed work space is,

according to the company, only possible due to

the introduction of EDS.

This uses hydro-mechanic drives to alter

pumps and motors, enabling LHDs to advance

when loading, whilst the flow is set back to

virtually zero. The drive and brake force is

supplied to all four wheels during loading,

tramming and braking, therefore the drive

energy is split to mechanically connected axles.

Using an intelligent combination of a

contemporary diesel engine, hydrostatic power

transmission and mechanical drive concept, fuel

savings, driver comfort and reduced exhaust

emissions are all achieved in underground

operations to a level not previously experienced.

Automatic transmission and a ‘push button’

reverse gear aid the handling and speed of the

LHD. After automatic hydrostatic deceleration,

the LF-10/11 will be accelerated in the opposite

direction without the use of a friction brake.

For safety regulations, there is a service brake,

but it is not in use under operating conditions.

The maximum possible speed is adjusted

automatically for incline or declines, with a

reduction in pedal pressure causing automatic

deceleration through the drive system.

EDS reduces energy costs significantly

through the optimisation of drives, engine rpm,

pump and hydro-motor regulation for any

mode of use, minimising the dissipation loss of

the drive system. This results in a reduction in

fuel consumption of 15-20%, depending on

operating conditions, which in turn lowers

exhaust emissions. Unlike conventional drive

systems, low engine rpms are sufficient to keep

the thrust or penetration.

Schopf has been developing and producing

robust LHDs for over 40 years. Its loaders are

offered with both air- or water-cooled diesel

engines, and work efficiently in narrow

working spaces, with bucket capacities ranging

from 2.7 m³ to 6.0 m³. Due to the company’s

centre oscillation technology, the front and the

rear sections of the vehicles are equipped with

two identical axles. Therefore the complicated

oscillating axle design of the rear axle is

unnecessary. This allows easy access to the

engine compartment as well as making the rear

vehicle section torsion free. Additionally,

gearbox and transmission can be used in one

module and do not need to be separated.

The drivers’ seat is arranged crosswise to the

driving direction – in contrast to many other

loaders – which increases the driver’s overall

visibility, enabling him to easily drive backwards

for the unloading process. This also aids

manoeuvrability. The LHDs come with open or

closed cabs, with air conditioning and comply

with the ROPS/FOPS requirements.

The SFL 65 has hydraulic orbitrol control,

heavy duty axles with POSISTOP and a Clark

gearbox with integrated torque converter. This

LHD can be equipped either with a Deutz

BF6M013 or the TCD 2013 engine which both

comply with the latest environmental

standards. It has a standard bucket size of 2.7

to 3.5 m³ and can also be equipped with a 2.9

m³ side-tipping- or a 2.9 m³ ejector bucket.

The ejector bucket can load into dumpers with

a box height of up to 2,400 mm with the use

of a special boom extension. With the side

tipping bucket, transport vehicles or skips

placed parallel to the LHD can be loaded

directly, without changing the driving direction

as the bucket hydraulically unloads across the

centre line. The SFL 65 is useful in narrow

tunnels, with a width of only 2,200 mm

making it an efficient loading and transport

vehicle for underground operations.

Another is the SFL 100, which has a width of

2,500 mm and a bucket capacity of up to 6.0

m³. It is equipped with proven components and

a 200 kW water-cooled Deutz diesel engine.

The loader has a payload of up to 12,000 kg

and can be used in tunnels with a cross section

of up to 4 m due to its easy manoeuvrability

and compact design.

Bucyrus is one of few companies with great

expertise in longwall shearers. Since moving the

shearer product to the Lunen manufacturing

facility in Germany, it has invested extensively in

the development of the next generation of

Electra® longwall shearers; with the first to roll

off the production line next year. Building on

GERMAN TECHNOLOGY

The reduced exhaust, noise and heat emissions of

GHH’s LF-10/11 lead to a significant improvement of

working conditions in the workplace

Schopf’s SF L65 has hydraulic orbitrol control, heavy duty axles with POSISTOP and a Clark gearbox with integrated torque converter

34 International Mining DECEMBER 2009


the success of those currently operating, the

first next generation shearer will be an updated

version of the successful Bucyrus EL3000.

In Australia, a market where Bucyrus

shearers have been very successful, over 500

Mt of coal has been produced with Electra

shearers since the first machine was delivered

in 1992. In 2008, four out of the top five

producing longwalls used Bucyrus EL3000

shearers. In the US, Electra shearers are

employed at some of the most successful

installations and, in particular, at some of the

most arduous operations in the market.

The EL3000 shearers will incorporate many

improved design concepts while retaining

proven aspects such as the rugged mainframe

for protection of the shearer’s major units, in

particular the electrical compartments. The

drive to ever increasing cutting heights is also

addressed, with the ability to cut in excess of

7.0 m in the high seam configuration of the

shearer. Once again, the flexibility afforded by

the mainframe configuration allows it to

achieve a wide range of cutting heights while

using the same fundamental components of

the shearer.

The shearer also benefits from the newly

developed control system, which brings the

shearer control in direct communication with

the well established PMC® family of products.

This provides a reliable and flexible longwall

system automation network.

Signal Peak Energy, Round Up, Montana, is

developing and installing equipment to begin

production from a new longwall mine in the

Powder River Basin. The mine will produce at

least 13 Mt of steam coal with the help of

Becker SMC - the American subsidiary of the

Becker Group - which provided a turnkey

installation that includes a 100 kV/40 mVA

substation with relay and control, switchgear,

section/belt power distribution centres, and

longwall power equipment. This will

standardise the mine on Becker SMC

equipment.

Bochum-based Eickhoff has always been a

worldclass supplier of gearing for all aspects of

the mining industry, including longwall shearers.

Designed at its US facility, the LISA shearer

electrical control system features a modularised

layout and design that greatly reduces the

number of wires, plugs and connections. This

new control system for Eickhoff shearers is now

in operation at an underground coal mine in

southwest Pennsylvania. So far, results have

been encouraging.

The various display screens provide information

on all parameters necessary to operate and

maintain the machine including motor currents,

winding temperatures, and oil pressures. In the

event of trouble, the on-screen diagnostics will

quickly lead maintenance personnel to the

source of the problem. An on-screen fault

message provides troubleshooting tips, location

of test points (by compartment) and a part

number of the component in the event that it

would need to be replaced. A typical fault

message is shown in the above diagram.

Processing and separationTwo separation companies have recently joined

together to offer a complete product range of

separation technology; including sensor

controlled separation and the magnet

technology for metals and minerals separation.

RTT Systemtechnik in Zittau and Steinert

Elektromagnetbau in Cologne will form RTT

Steinert. This will bring together RTT’s years of

experience in the development and marketing

of near infrared technology and Steinert’s years

of experience in the area of sensor sorting and

magnetic separation.

Steinert will be leading the worldwide

aspects of the new company. “We have

created the unique opportunity worldwide to

offer a comprehensive product range for the

mining industry, as well as metal processing

and domestic waste from one source”, Franz

Heiringhoff, CEO from Steinert, pointed out.

“The global sales presence as well as the

possibilities of Steinert’s worldwide service were

a relevant argument to look for a closer co-

operation with Steinert”, emphasised Bert

Handschick, CEO of RTT.

Moving to a company expanding overseas,

allmineral, the Duisberg based provider of dry

and wet processing equipment, with such

products as its alljigs®, allflux® and allair®, in

June, set up an Indian subsidiary, allmineral

Asia, in a joint venture with Jyotirmoyee

International. The company is now responsible

for the marketing, supply, project management

and service for all of allmineral’s mineral

beneficiation solutions in India and Southeast

Asia.

allmineral’s Executive Director and allmineral

Asia’s new Chairman, Heribert Breuer

GERMAN TECHNOLOGY

The next generation of

Bucyrus Electra shearers will

support and advance current

state-based automation

technology. Its advanced

control network allows the

integration of all new

developments - such as coal

interface detection and radar

comments, “We will meet the ever-

increasing demand of our customers in Asia

by enhancing our strong presence and

raising the level of service and quality even

higher. By having our own office in India,

we are taking steps to expand our already

very successful involvement in Asia.”

“This is made possible by the fact that

allmineral Asia has kept on the excellently

trained and experienced personnel of Hari

Machine’s mineral beneficiation branch,”

Sabayaschi Mishra, Head of allmineral Asia

explains. “Hari Machines remains the

manufacturer of our equipments.”

The two companies – allmineral and Hari

Machines – have been collaborating for a

number of years already. The partners

supplied iron ore processing equipment to

Jindal Steel & Power for its 9.97 Mt/y plant,

as well as to Brahmani River Pellets for its

3.62 Mt/y processing plant in Orissa, which

will process previously unusable raw

materials for pellet production with the help

of this machinery. In total, the partnership

has carried out 30 iron and coal processing

projects across India since 2005.

Cyanide effluent is a major worry to many

mining companies. CyPlus® has developed

several processes for cyanide effluent treatment

(CET), which are suitable for use in cyanide-

containing ore pulps. These have been

developed as conventional methods, like H2O2,

are impractical, as prohibitively high

reagent consumption causes product

decomposition. After collaborating in the

field of CET with Inco Tech Canada for

many years, CyPlus developed the

CombinOx® process and then acquired

the knowhow for designing and operating

the SO2/AIR process.

CyPlus has succeeded in

commissioning two CET Cold Caro's Acid

systems for USA-based Jaguar Mining at

its Turmalina and Paciencia gold-mining

operations in Brazil. Cold Caro's Acid is a

powerful oxidant that is produced in-situ

by adding hydrogen peroxide to

concentrated sulphuric acid. It is used in

gold extraction to convert cyanide into

cyanate. “The CyPlus system is a proven

process that achieves a yield of more than

80% of Cold Caro’s Acid,” says Stephen

Gos, Manager of Technology Solutions at

CyPlus in Hanau-Wolfgang. The

advantage of the CyPlus system is that

the heat from the reaction can be

controlled and kept at low levels, thus ensuring

safe operation.

A feasibility study conducted at CyPlus

laboratories shows that the Cold Caro's Acid

process outperforms other effluent-treatment

systems. Basing its decision on the study and


GERMAN TECHNOLOGY

CyPlus has commissioned two CET Cold Caro'sAcid systems for Jaguar Mining at its Turmalinaand Paciencia gold-mining operations in Brazil

GHH Fahrzeuge GmbH – Partner for underground mining solutionsRELIABLE. PRODUCTIVE. PROVEN.The new LF-10/11 with EDS concept. For highest break out force and lowest operating costs in its class.EDS – The new drive line concept for underground.

www.ghh-fahrzeuge.de

EFFICIENT DRIVE SYSTEM

Emscherstr. 53, D-45891 Gelsenkirchen, GermanyTel: +49 (0)209-389 07-0 . Fax: +49 (0)209-389 07-109

http://www.ghh.fahrzeuge.de

the basic engineering package, Jaguar chose to

install the system. Besides keeping cyanide levels

in check, it is highly efficient as regards hydrogen

peroxide and sulphuric acid consumption.

“We require low cyanide discharge levels for

our operations and it is essential to perform

this economically. With the CyPlus Cold Caro's

Acid systems, we expect to reduce reagent

consumption by more than 30%, achieving the

same low cyanide levels of 10 ppm or better.

The results from the commissioning phase

indicate that we made the right choice,” says

Mauro Salim, Project Manager for both of the

Jaguar Mining operations.

Endress+Hauser supplies industrial

measurement and automation equipment. It

offers comprehensive process solutions for

flow, level, pressure, analysis, temperature,

recording and digital communications;

optimising processes in regards to economic

efficiency, safety and environmental protection.

Application examples include:

■ Flow

– Prowirl vortex flow meters – measuring

air injection for agitation in flotation

cells

– Metering of sulphuric acid with Promass

coriolis mass flow

– Metering of abrasive slurries

■ Analysis of process and environment

– In slurries to control acid or lime milk

addition with CPS pH sensors

– Turbidity and sludge level measurement

in thickeners

– Acid concentration measurement in

slurries using CLS conductivity sensors

and Liquisys M transmitter

– Dissolved oxygen monitoring of effluent

to rivers and ground using Liquisys M

transmitters and COS sensors

■ Levels

– Coal in bunkers or at flotation cells with

Prosonic ultrasonics

– Long range ore pass levels with

Micropilot M solids radar

– Sulphuric acid tank levels with

Micropilot M radar

– Level and slurry density in autoclaves

and flash tank levels with Gammapilot

M radiometric sensors

■ Pressure

– Hydraulic and conveying pressure in

pipes and pneumatic loading lines for

powders with Cerabar M ceramic cell

version

– Differential air pressure control across

the grinding mill with Deltabar S

■ Temperature

– In slurry thickening tanks with tough

Omnigrad TAF and TC sensors.

Going up in scale, Engineering Dobersek,

a plant engineering company out of

Mönchengladbach has delivered two new

Conticlass® System plants to Ural Mining and

Metallurgical Co (UMMC) in Russia’s Ural

region. These plants are to increase the

quantity and throughput of copper- and zinc-

concentrates in the company’s mill. This system

gives continuous classification of ores by

constant pressure at the hydrocyclone inlet, as

well as high density in the cyclone overflow. In

addition, Dobersek says that approved pumps

achieve ten times the life of conventional

systems, by using a rotation speed control of

the applied rotary pumps, pressure fluctuations

are avoided and cost-intensive downtimes are

minimal.

In October, the company also received an

order for a coal treatment and loading plant in

Kakanj in Bosnia Herzegovina. The project’s

objective is to reduce pollution and transport

costs which are caused by full-time trucking.

The commissioning of the modern coal

treatment and train loading plant is planned for

early 2011.

Bulk handling Haver & Boecker, a manufacturer of screening

equipment, has reworked its series of free-

swinging screens in the Haver® Screening


GERMAN TECHNOLOGY

http://www.tk-mining.com

Group (HSG). These machines now

benefit from proven and tested

components being combined to

create reliable and field tested

specialty machines. Some of the other

developments include a drive that

enables amplitude-speed

combinations in a wider range of 2-

10 mm. This design accommodates

new working conditions as well as a

reduction in sound emissions. The

company has also devised a new

wear protection system that

effectively protects the machine,

which can be retrofitted to existing

systems. This ensures that when worn

components need replacing, there is

minimal downtime.

The screen frame of the HSG

machines is engineered in a traverse

design. The deck is clamped onto the

frame with a patented retaining bracket instead

of having welded seams. This supports the

system, as well as allowing the brackets to take

up several positions. In addition, the screen

frame components, such as feed and transfer

plates, are engineered to accommodate load

bearing.

The deck structure of its NIAGARA T-CLASS®

has been adapted to fit all conventional

screening surface systems in the HSG range.

These are essentially:

■ Side-tensioned wire mesh, polyurethane or

rubber panels

■ Screwed-on or clamped perforated plates

■ Clamped harp or special designs

■ Screen modules made of polyurethane (PU)

or rubber

■ Modular frame with other screening media

(e.g. PU base frame with harp wires).

The machines are designed with the help of

the NIAproject design software. This has a

calculation model that is used to analyse the

separation of the materials and then estimate

the available screening area. This helps to select

the right machine and parameters for the

application.

There is a growing acceptance of high

pressure grinding rolls (HPGR) in the minerals

industry. KHD Humboldt Wedag, a

manufacturer of HPGR technology, introduced

its Roller Press in 1984 to the cement industry.

Beyond the high unit throughput, the low

specific energy input and the reliable and

efficient operation, further benefits of HPGR in

minerals processing include:

■ Fine crushing through partial recirculation

■ Significantly enhanced metal recovery

■ Improved downstream processing.

In October 2009, Shandong Gold Group in

China awarded Humboldt Wedag Germany, a

subsidiary of KHD-Group, the contract for the

supply of a Roller Press (RP) for tertiary crushing

of gold ore. This will be the first application of

HPGR technology in the gold industry in China.

The new RP system will be installed as the

tertiary crushing stage at the 8,000 t/d crushing

and grinding plant of Sanshandao gold mine in

Shandong Province.

KHD´s scope of supply comprises a RP, type

RPS 7-140/110, equipped with its patented,

wear resistant roller surface with stud-lining

wear. The press with a throughput rate of up to

800 t/h will be operated in closed circuit with

partial product recirculation without

the need for screening.

Another HPGR circuit in gold ore is

presently being commissioned by KHD

at the Vasilkovka gold deposit in

Kazakhstan with two RP 16-170/180s

operating in parallel in closed circuit

with partial product recirculation. The

machines are designed for a

throughput of 1,440 t/h. The RPs are

installed as the tertiary crushing stage,

before fine grinding and gold

extraction. The high reduction ratio and

the low energy input achieved through

the use of HPGR units has provided a

promising basis for further applications

in copper ore processing in Kazakhstan.

One of KHD’s successes in HPGR

installations is Compania Minera

Huasco’s installations at Los

Colorados iron ore deposit in the

Atacama region of northern Chile. The RP 16-

170/180, equipped with roller surfaces with

stud-lining operates in closed circuit with

vibrating screens. It has been in operation since

November 1998, with a throughput of up to

2,000 t/h.

Norbert Becker, Vice President for Process

Solutions Mining, Siemens says that “In terms


GERMAN TECHNOLOGY

Haver & Boecker screen deck in combined screening

surface configuration

Norbert Becker, Vice President for Process Solutions

Mining, Siemens says that “Wherever energy savings,

availability, reliability, reduced equipment wear and

difficult terrain are an issue, gearless drive systems are

the most economical drive option for large belt

conveyors”. Pictured here, the up hill conveyor

gearless drive system for the Prosper Haniel

underground mine in Germany

of energy efficiency and availability, gearless

drive systems (GD) are a logical next step in the

evolution of conveyors.” Belt conveyors are

increasingly being used in operations due to

their efficient and cost-effective qualities;

however Becker sees GD as a way to further

improve efficiency.

Becker: “In the mid 1980s Siemens built the

first and the last up hill conveyor GD system,

for the underground mine Prosper Haniel in

Germany. This is still in operation and has

remained since day one, extremely efficient and

very reliable. Subsequently, popularity for the

GD solution for conveyors waned, due to

various circumstances like capital cost and

power requirements. Today however, interest

has picked up again.

“In the past 30 years Siemens has

continuously developed [its] GD systems and

gained a lot of experience in low speed

applications like mill drives, mine winders,

bucket chain excavators and draglines. This

know-how is also applicable for GD conveyors

solutions. In general the GD solution is based

on a low speed synchronous motor, fed either

by a cyclo-converter, or by a voltage source

converter dependent on line conditions and

special drive features.”

As there is no gear between pulley and

motor, and the motor has no bearings, the

drives benefit from the following:

■ No significant inrush current during conveyor

start-up due to vector controlled drive

■ No energy loss during start-up within the

secondary resistor starter or fluid coupling

■ No energy loss due to load sharing during

operation.

Becker explains that “Compared to

conventional conveyor drives, energy

consumption can be reduced by up to 20%,

depending on the specific conveyor application.

This is achieved by eliminating gears and load

sharing resistors as well as matching the

conveyor speed to the material flow. Slip

starting can also be avoided completely.”

Tenova SEMF, part of Tenova TAKRAF, a

leading supplier of mining and bulk handling

technology, products and services, has recently

obtained the Practical Completion Certificate

for its QBH coal stacker installation located in

Brisbane, Queensland. The long travelling twin-

boom coal stacker with tripper was designed

and constructed for the Fisherman Islands

storage facility expansion, part of the

Queensland Bulk Handling (QBH) coal terminal,

fully owned by New Hope Corp. Tenova SEMF’s

contract was for design, fabrication,

mechanical fit-out, delivery, erection and

commissioning, and formed part of QBH’s

wider stockyard upgrade, which is expected to

be completed by late 2010.

The stacker was successfully delivered three

weeks ahead of schedule; the nominally 100 m

wide stacker has twin booms and a capacity of

2,750 t/h. The stacker is rail mounted, travelling

up to 165 m and will generate two 20 m high

parallel coal stockpiles. This machine is a key

component of the whole expansion plan for

the coal terminal.

Open-pit technologyA Komatsu PC 8000 mining shovel built in

Germany is being successfully operated at

4,000 m above sea level (asl) in a Chilean

copper mine. This is the first super large

hydraulic excavator of its class working in such

altitude where it is digging rock and

overburden. The machine is loading Komastu

930 E haul trucks with an overall payload of

around 290-t in four passes.

The PC 8000 is able to operate in this

environment due to the special Komatsu shovel

design and there are likely to be more shovels

operating in the South American Andes as well

as being involved in one of the world’s largest

gold projects between the Chilean and

Argentinean border at 5,200 m asl.

From 2010, Komatsu Mining Germany will

offer all shovels with Tier II emission certified

diesel engines as an option. With the

implementation of Tier II, all machines will be

equipped with the Komatsu vehicle health

monitoring system (VHMS) as standard,

contributing to efficiency. The customer has


GERMAN TECHNOLOGY

Komatsu shovels are not just applied in extreme

conditions. They are recognised around the globe as

reliable, efficient machines. This is emphasised by the

fact that the company is about to ship its 75th PC

8000

Liebherr’s new R 9250 Etakes only three bucketloads to fill an 80-t dumptruck, or four to fivebucket loads for a 120-tdump truck

access to VHMS data and can be proactive with

preventive maintenance and service.

In 2009, Komatsu introduced a new

comfortable operator cabin. The cabin has a

spacious design with a base area of about 3.7

m². Major improvements are: increased all-

around visibility, fully-fledged trainer seat and

reduced maximum noise level of 76 dB.

Furthermore, the machine interface has

changed slightly in order to provide a

comfortable and productive environment for

operators.

With the launch of the mining excavator R

9250 at Bauma 2007 and the presentation of

the first shovel version at MINExpo 2008,

Liebherr is now making this successful model

available with an electric drive unit. Partly

significant fuel price increases and an increasing

awareness of alternative energy sources have

prompted the company to produce the electric

version. Liebherr engineers drew upon many

years of experience to produce the R 9250 with

the development of the R 9350 E being very

influential.

The R 9250 E provides a motor output of

nominal 1,050 kW (nominal excavator power

of 1,100 kW) at 6,000 V and 50 Hertz. The AC

squirrel cage motor, with the long motor

lifetimes, requires only minimal maintenance

contributing to increased uptime and machine

use. Furthermore, mines with access to low

cost electricity can benefit from lower operating

costs in comparison to diesel powered units.

The electrical motor is started by a starting

transformer. All electrical installations are

protected on IP 55 EN 60529 Standard. The

electrical compartments are sealed and secured

to withstand tough mining applications.

The standard electrical version of the excavator

is equipped in backhoe configuration with a 9

m gooseneck boom and a 4-m stick. In face

shovel configuration the machine is equipped

with a 6.3 m swing boom and a 4.2 m shovel

stick. Both have a nominal bucket capacity of

15 m³; however this can be customised to suit

material properties and mine site requirements.

The first units have been delivered to Russia

and have commenced operation.

One of the country’s bigger manufacturers

has been taking part in an interesting coal

project in Turkey. Park Teknik, part of Ciner

Group company, won the tender to operate


GERMAN TECHNOLOGY

GEOSCANTM THROUGH BELT ELEMENTAL ANALYSER

MINERALSCAN MODEL 1500 NATURAL GAMMA MONITOR

TBM 200 SERIES MICROWAVE MOISTURE MONITORS

Real Time On-belt Analysis

for Process Control Moisture & elemental analysis Metal accounting Non-contact systems Ores & concentrates Coal & Power applications Product support packages Over 850 analysers installed in

51 countries

[email protected] www.scantech.com.au

ph: +61 7 3710 8400 fax: +61 7 3710 8499

Wirtgen’s 4200 SM surface miner was premiered in

March at the company’s headquarters in Windhagen.

For a full report on the machine see International

Mining’s May issue, pp34-35

http://www.scantech.com.au

the Cöllolar coal mine in Turkey. This will fuel

the Afsin Elbistan thermal power plant. The

tight time frame of this operation necessitated

a solution that ensures the timely coal supply of

the power plant.

After many discussions, ThyssenKrupp

Fördertechnik, Business Unit Mining presented

a solution for Cöllolar involving a Truck Dump

Station (TDS). This company won a contract for

four stations to be fed with either overburden

or coal. Requirements included:

■ The height of the plant had to be as low as

possible, to reduce costs for the retaining

wall and the excavation of the pocket, while

at the same time considering the material

flow and providing steep walls for the

hopper and the crusher discharge chute

■ To fill the feed hopper with the existing truck

fleet with a capacity of around 17 m³/truck;

no small task considering the required

handling rate of 5,600 m³/h

■ To minimise backing and clogging of the

sticky material

■ To design a crusher unit that will prevent the

downstream conveyor from being fed with

oversized material

■ Relocation of the TDS within the shortest

possible time and at low costs

■ To design a retaining wall that can be

reused.

The result was a TDS that can

be fed by five trucks

simultaneously. Each TDS has two

feed hoppers and type DRS 950 x

2500 CS sizers underneath that

are fed directly by the dump

trucks. Hoppers and sizers are

mounted on the same frame so

that a transport crawler, also

within the scope of the order, can

relocate the entire unit. To

minimise backing and clogging of sticky

material, the hopper walls are steep and

supplied with air canons and heating plates for

winter operation. The sizer drive units are

frequency controlled to regulate the material

flow onto the overland conveyor.

Maintenance platforms, which can be

installed for service on the complete sizers,

were also within the scope of the order. A

curved beam with hoist is mounted above the

sizers for minor maintenance work. The

retaining wall is made of single concrete

elements, with its size and weight allowing for

transport by normal trucks. The client has

decided to purchase an additional set to reduce

preparation time for the new location.

The MTU Series 1600 engine was released

earlier this year. This diesel engine for the off-

highway market, with power outputs between

270 and 730 kW, expands the company’s

product portfolio in the lower power range. It

is the smallest engine manufactured by MTU.

It comes in an in-line configuration with six

cylinders as well as in V-configurations with eight,

ten and 12 cylinders, covering a displacement

range from 10.5 to 21 litres. The 1600 complies

with the current exhaust specifications of EPA

Tier 2 (power output above 560 kW) and EPA

Tier 3 (power output below 560 kW) without

the necessity of exhaust after-treatment

measures. Thanks to its modular design and

standardised interfaces, it is open to future

integration of exhaust after-treatment systems.

RUD-Erlau notes that earthmover tyres

require special attention. Without tyres,

RUD-Erlau’s GARANT PROTRAC X18 for traction and

safety

SCHOPF Maschinenbau GmbH • Parkstrasse 19 - 21 • D-73760 Ostfildern/GermanyPhone +49 (0) 7 11 3 40 00-0 • Fax +49 (0) 7 11 3 41 10 87 • www.schopf-gse.com • [email protected]

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SCHOPF SFL 60 XLPExtra Low Profile U/G LoaderPayload 6000 kg / 13216 lbsBucket volume (SAE) 2.7 m3 / 3.5 cyd

Also available in flameproof version

GERMAN TECHNOLOGY


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loaders, trucks and graders are not much more

than ‘grounded’, lumps of iron. And there is so

much that can go wrong. Badly fitted or poorly

inflated tyres can affect handling safety, destroy

rims, over-heat, burst and raise fuel costs. No

matter how well-made, unprotected tyres will

wear too quickly and can be destroyed and, in

some conditions, become costly scrap in an

instant, the company says.

Certain plant managers see tyre protection

and traction chains as essential accessories to the

extent that they are now a common sight, not

only in Chile and South America but anywhere

in the world where the working environment is

tough on tyres. With 65% of the world

market, it is most likely that the tyre protection

chain (TPC) you see in action will be a RUD-

Erlau patented design, the company claims.

In Chlie, Antofagasta, Codelco, Escondida

and other copper miners count amongst RUD-

Erlau’s many long-term customers. Wheel

loaders dependant on RUD-Erlau TPCs, include

CAT 992s, CAT 994s and LeTourneau 1400s

and 1850s. The company reports that the close

mesh of the FELS CROWN X22 – RUD-Erlau’s

largest diameter forged link - provides

complete protection from abrasion and sudden-

death, sidewall piercing.

There are CAT 824 and 834 wheel dozers

fitted with RUD-Erlau’s GARANT, GARANT 10

ROYAL X16 and GARANT 10 IMPERIAL X18.

These 16 and 18 mm diameter links can be

configured as tight or open mesh depending

on whether ground conditions make traction or

abrasion the most important considerations.

Losing control of a haul truck with a 400 t

payload is a frightening experience and

maintaining traction and operating safety over

the winter ice of the high Andes is of real

concern. For safety, Komatsu 830 and 930 and

CAT 797 haul trucks rely on traction chains

such as RUD-Erlau’s GARANT, GARANT 10

CROWN X22, GARANT 10 TERRAPLUS X 22,

and PROTRAC X18.

In 2009 alone, RUD-Erlau delivered and fitted

over 50 sets of TERRA PLUS to Chile.

Developed in response to Chile’s mining

conditions, TERRA PLUS, with its unique self-

cleaning Z links and deep-biting studs, is RUD-

Erlau’s latest and most effective answer to

beating snow, ice and soft-ground.

RUD-Erlau’s special duty TPCs include the

FELS Toro X19 for all-round protection of low

profile tyres used in underground duties.

After factoring in investment in the chains

and a slight rise in fuel consumption, analysis

shows that operations can expect at least 10%

improvement in operating costs. The gains arise

from reducing accidents and less damage to

plant and injury to personnel, more than

doubled tyre life and assured plant availability.

With high quality protection, operators can

save more dollars by using part-worn tyres.

The links must be as light and as hard-wearing

as possible and have consistently high-quality

welding done by the most modern methods.

Though headquartered in Sweden, Sandvik

Mining and Construction has a big presence

in Germany. Its production unit in

Bergneustadt, uses the best of innovative

technologies and expertise to provide

comminution machines like the series of CR800

hybrids, CR600 sizers, CR400 roll crushers and

CM400 hammer mills. The factory is situated in

the district Nordrhein-Westfalen, in the very

heart of the German iron and steel industry.

The area possesses a long tradition of German

machine engineering and manufacturing. In

addition, worldclass technical universities in the

region provide local companies with a

continuous stream of highly educated

engineers. The factory in Bergneustadt is such

an example. Production started in 1947 under

the name Aubema. Today it is an important

part of Sandvik, and up to date more than

7,000 machines have been distributed to over

70 countries. It also manufactures fully-mobile,

semi-mobile or fixed crushing stations and

recently delivered a semi-mobile coal crushing

station to the Baiyinhua coal mine in one of the

largest coalfields in Inner Mongolia.

At Port Warratah in Newcastle, Australia, the

world’s largest export coal terminal, as part of

an expansion of the port, Sandvik was

commissioned in 2007 with delivering three

new giant bucketwheel reclaimers, the biggest

for coal handling in Australia. These are

currently being set up on site.

There was also the matter of the old

equipment, which is 26 years old, to be sorted

out. This is where Sandvik’s Saarbrücken centre

of competence for the new area of ‘Global

Technical Services – Materials Handling’

stepped in. The ‘deconstruction’ of two old

stackers with an operating weight of 829 t

each in the summer of 2009 and two old

bucket wheel reclaimers, each weighing 1,782

t in the spring of 2010 was included in this

contract. This is being co-ordinated between

Sandvik Saarbrücken (technology) and Sandvik

Perth (project execution).

Following Wirth becoming a fully controlled

subsidiary of Norwegian company Aker

Solutions in early 2009, the German

manufacturer has been incorporated into Aker

Wirth. In June, Per Harld Kongelf, Executive

Vice President of Aker Solutions said: “Our

acquisition of Wirth complements and expands

our customer offering. Aker Solutions is now

one of only two suppliers in the world of

complete drilling packages. In addition, the

acquisition of Wirth’s mining and construction

expertise strengthens our presence in the

process and construction markets.”

For more than 20 years Wirth has been

successfully collaborating with Aker Solutions on

drilling packages. By formalising this connection

through acquisition, the goal is to strengthen

the existing collaboration and expand it to all

of Aker Solutions drilling activities globally. IM

The semi mobile crushing station at the Baiyinhua coal

field in Inner Mongolia, like the one pictured here,

consists of a complete primary crushing station based

on the Sandvik centre sizer CR610 with a crushing

capacity in excess of 2,200 t/h

GERMAN TECHNOLOGY

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