Tag Archives: Germany

Metso Outotec slurry pumps to treat tails at SevGOK iron ore project

Engineering Dobersek in Germany and Severniy Mining and Processing (SevGOK) in Ukraine have selected Metso Outotec’s mill discharge pumps for Severniy’s greenfield process waste thickening plant, the OEM says.

Metso Outotec’s pumps will be used to pump the iron ore concentrate plant’s waste sludge into the settling ponds from the thickeners. The 22 pumps to be delivered by Metso Outotec include 10 large high-capacity MDM700 pumps. Together, the pumps are capable of handling a total volume of 117,500 cu.m/h of waste sludge.

“SevGOK’s complex is the second of its kind in Ukraine, and Engineering Dobersek in Germany has designed it,” Axel Stappen, Managing Director, Engineering Dobersek GmbH, says. “With this investment, SevGOK aims to decrease environmental impacts and costs by lowering energy consumption and water usage. They chose Metso Outotec pumps because of their reliability and efficiency, and the good support Metso Outotec has provided in their previous projects.”

Michael Nienhaus, Head of Sales, Slurry Pumps, Germany, Metso Outotec, says: “We are delighted to have been selected to supply our MD series pumps to SevGOK’s project. To give an idea of the size of an MDM700 pump, it can weigh as much as 31 t and be 2.8 m in diameter, and have an impressive pumping volume of up to 9,650 cu.m/h. The MDM pumps operate in very demanding conditions, and we’ve designed them to operate reliably and to withstand exceptional wear.”

Metso Outotec mill discharge pumps have been designed for mill circuit applications, such as SAG/ball mill discharge pumps and hydrocyclone feed. Special emphasis has been placed on components that have to withstand exceptional wear from coarse heavy solids and flow turbulence, the company says.

German mining OEMs to benefit from climate, digitisation focus, Schulte Strathaus says

Those involved in the mining equipment industry in Germany are optimistic about future demand for their products, with only state-of-the-art technology able to provide the raw materials needed for climate protection and digitisation, the VDMA Mining Association reports.

This is despite expectations of a decline in sales of for 2020, the association said.

This industry importance was also emphasised by the Chairman of the VDMA Mining Association, Dr Michael Schulte Strathaus, during the association’s annual press conference at the Zeche Zollverein in Essen, Germany, earlier this month.

Due to the pandemic, predictions for 2021 are hard to make, but Schulte Strathaus said he was sure incoming orders and sales will develop positively in the future.

“We ensure that raw materials can be mined and processed,” he said of the equipment makers within the association. “Mining equipment is becoming increasingly environmentally friendly and is making its contribution to climate targets, for example through alternative drives and lower energy consumption in mines.”

Production and sales developed well in 2018 and 2019 for the mining companies from Germany, the VDMA said. Yet, contrary to expectations, new business and incoming orders fell sharply at the end of 2019.

While the industry was still expecting a subdued development with stagnating sales at best, COVID-19 put additional pressure on these companies.

Over 2020, companies managed to close the interrupted supply chains again and to organise COVID-19-compliant production. They largely switched communication with overseas customers to web-based procedures. By the end of the summer, the industry was sending out very different signals: from virtually unchanged sales plans and expectations, to a drop in sales of 30% or more. Overall, the industry expects a decline in sales of 10-15% in 2020 to €4-4.5 billion ($4.8-5.4 billion).

The EU countries, the US, Russia, and China remain among the largest export markets for German mining manufacturers. Australia demand surprised this year, reaching second place among the individual markets, ahead of China and Russia. With an export share of 96%, manufacturers in Germany are dependent on foreign business.

In the EU, mining production has remained stable over the last 20 years. In the summer, the EU Commission announced it wanted to secure Europe’s supply of critical raw materials. To this end, the procurement of raw materials in the EU is to be strengthened, the VDMA said.

In the US, Schulte Strathaus believes the mining industry is on the brink of upheaval.

“With Joe Biden, the country will commit itself to climate neutrality, and large parts of the announced funds of around $2,000 billion will be channelled into the development of clean energy technologies,” he said. “This creates opportunities for our mining equipment manufacturers in Germany. However, they must make more effort to open up new sales areas or expand existing ones.”

Following a very successful 2019 with exports of around €97 million, deliveries to Australia fell to €68.8 million in the first eight months of 2020. Schulte Strathaus was confident Australia customers would again be more interested in mining technology from Germany from 2021 onwards, as the reluctance to establish new supplier relationships due to the pandemic eases.

Russia is currently a very difficult market due to sanctions, political disagreements, and the weak Rouble, the VDMA said. Travel restrictions and the uncertainty that deliveries from Germany could be stopped at any time make business relations risky for companies in Russia, it added.

In China, coal mining was way ahead of the wider Chinese mining industry. While the country is recovering from COVID-19, the mining sector generated sales of around €309 billion and a profit of around €30 billion in the first eight months of the current year. Manufacturers from Germany were unable to benefit from this, the VDMA said. By August, exports had only reached €67.7 million, a drop of 45%. Schulte Strathaus, nevertheless, sees good chances for positive German equipment sales development, with China banking on digitisation and unmanned operation of mines.

In addition to all the positives that come with adopting new technology, social benefits are increasingly becoming the focus for manufacturers of mining machinery, according to the VDMA.

“With our machines, we guarantee a climate friendly and secure supply of high-tech raw materials because, without them, there can be no energy transition,” Schulte Strathaus said.

Gensource signs up K-UTEC, Koeppern and Ebner for Tugaske potash project

Gensource says it has engaged a consortium of world-class potash process design and equipment fabrication companies to work together to provide a design-supply-commission package for the entire process plant at the Tugaske potash project, in Saskatchewan, Canada.

The kick-off of engineering work for the major process equipment package is another milestone for the project, the fertiliser development company said.

Gensource previously announced advances in the development and financing of the Tugaske project, with KfW IPEX-Bank and Société Générale, joint lead arrangers for the project debt, nearing completion of their due diligence process.

The total senior debt financing for the project is expected to be supported by export insurance coverage with the German Export Credit Agency (ECA), Euler Hermes.

To satisfy a significant portion of the German export requirement, Gensource has elected to work with a consortium of three German-based design and equipment fabrication companies, namely: K-UTEC AG Salt Technologies, Koeppern GmbH & Co KG and Ebner GmbH & Co KG.

“Individually, these companies represent world-class capabilities in their specific areas of expertise, whether in the design of potash and salt processing plants or the design and fabrication of equipment,” Gensource said.

Together, the three companies known as KKE have the capability to supply the entire main process plant in a single design-supply-commission package, the company said.

K-UTEC AG Salt Technologies will look at the physical chemistry, overall process development and engineering, including practical bench scale testing, for the project; Koeppern will be engaged for drying, compaction, and screening process design and compaction equipment design and manufacture; and Ebner (tour of Ebner fabrication facility in Eiterfeld, Germany, pictured below) will be in charge of cooling crystallisation process design and crystallisation equipment design and manufacture.

“Based on the combined experience and capabilities of KKE, Gensource saw an opportunity to not only work with these top-tier companies and have this work qualify for ECA coverage, but also to simplify the number of project interfaces by packaging the entire process plant into a single design-supply-commission contract package,” Gensource said.

“Together, these companies provide a complete solution: from receiving the raw brine from the solution mining wellfield all the way through to a final potash product, meeting the off-taker’s specifications, ready for storage and shipping.”

Additionally, by packaging the entire process plant into one export contract, Gensource says it de-risks the project through obtaining a process guarantee from KKE for product quality and process plant throughput.

To advance the scope on this process plant package, Gensource has initiated the first phase of engineering with KKE, which will start the detailed process and equipment design, leading to the fabrication and ordering of key equipment for the process plant.

Advancing the scope of this package supports a development timeline that targets production from the Tugaske project in late 2022, supplying product to Tugaske’s off-taker and future equity partner, Helm Fertilizers.

The efforts of the KKE group will be integrated into the project by Gensource’s key project delivery partners: Engcomp Engineering & Computing Professionals, the lead engineering and design consultant for the project; and South East Construction (SEC), the general construction contractor for the project, it said.

“Together, Gensource, Engcomp, and SEC are acting as an integrated team, responsible for the overall execution and delivery of the project,” Gensource said, explaining that both Engcomp and SEC were seasoned engineering and construction professionals in the Saskatchewan potash industry.

Mike Ferguson, President & CEO of Gensource, said: “The three companies of the KKE group have unrivalled global experience in the potash and salt industries and bring their tremendous know-how, experience and proven track record of success to our project.

“Together with Gensource, Engcomp, and SEC, KKE rounds out the world-class potash team that we have established, which will no doubt deliver a world-class sustainable potash production facility in Saskatchewan via the Tugaske project.”

Like other Gensource module designs, the Tugaske project will produce a minimum of 250,000 t/y of saleable muriate of potash product.

Flexco lays ground for growth in Europe with bigger Rosenfeld facility

Flexco’s Europe division has recently moved into a larger complex in Rosenfeld, Germany, as it addresses existing space constraints and allows for future growth of the operation.

Joerg Schairer, Managing Director of Flexco Europe GmbH, said: “The reasons behind our decision to build it were complex. We have always pursued the goal of becoming the most important contact in the sector for operations who want to maximise the productivity of their conveyor systems. The new building will help us to achieve this goal, because it has the space that allows us to manufacture new, innovative products that solve our customers’ biggest conveyor challenges – and we’ll also be able to offer our customers the best possible support in our modern training centre.”

The facility is 10,741 sq.m, with 3,200 sq.m dedicated to administrative functions, while the other 7,500 sq.m houses production, storage, and shipping. The location more than doubles the size of all departments and provides opportunities for workforce expansion, the conveyor-focused specialist said.

“The new facility gives us space for more than 100 attractive jobs,” Schairer said. “We have increased our workforce by 15% in the past 12 months and, in the future, will be doubling the number of apprenticeships we offer.”

With construction of the new building, Flexco was looking for a more modern, open design that would optimise the exchange of information between its employees and customers, it said.

“Since Flexco has a long history of manufacturing innovative, high-quality products, the design team wanted to make sure the use of modern technologies were high on the list of requirements,” the company said. The resulting facility encompasses all these features, with more to come, it added.

“We’ll be developing the site into one of the most modern competence centres in Europe for belt conveyor productivity in a variety of industries and applications,” Schairer said. “We understand the challenges of customers – from food, to parcel handling, to laundry, to mining, and more – and support them in finding safer, more efficient solutions. Flexco University, online training courses, webinars, on-site trainings, and industrial networks are just a few of the offerings through which our customers can benefit from our experience and know-how.”

Epiroc’s new hammers to ‘dramatically change profitability in DTH drilling’

Epiroc says its new COP M series of flexible down-the-hole (DTH) hammers is easily adapted for use on different rigs and in different drilling conditions – and set to boost productivity for mining companies.

Mining companies seek to minimise the cost of drilling holes by opting for fewer and larger holes to reduce the total number of drill meters, and increase efficiency and profitability, according to Epiroc.

“It’s about ensuring maximum utilisation of the rig and keeping it operational with minimum interruption,” said Davood Mohammadi Balan, Percussive Service Manager at Epiroc.

However, traditional DTH hammers involve repeated consumable replacements and a large inventory. Shifting to a new hammer for each rig type or drilling condition is costly to mining companies.

The new COP M hammers from Epiroc will dramatically change profitability in DTH drilling thanks to their innovative flexibility, according to the company.

“These new hammers are a step towards a change in operational flexibility by being easily adapted to different rig types and drilling conditions,” Balan said.

Each hammer in the new range can be used on a wide range of DTH drill rigs thanks to a conversion kit located inside the hammer.

Fredrik Gransell, Product Line Manager, DTH, Epiroc, said: “By adapting the hammer to a specific rig, the rate of penetration (ROP) is optimised.”

Together, the new products, COP M6, COP M7 and COP M8 – where M stands for mining and the number for the tool’s dimension – optimally cover drilling needs in the 6.5-10 in dimension range.

Gransell added: “The new COP M series adds the flexibility of selecting the right tool for any given situation. It’s a revolutionary innovation in DTH drilling.”

“At a small investment, mining companies can tap into top-quality technology from the leading provider – and boost profitability to a whole new level,” concluded Balan.

Still within the COP M Series, but for smaller diameter holes, Epiroc also used the recent Bauma fair in Munich, Germany, to showcase its new COP M4 DTH hammer for soft-rock applications.

The DTH hammer offers mining and construction companies the highest durability for both hammer and bit – with maintained ROP, the company said.

As the name implies, the hammer’s dimension is 4 in, making it useful for most soft-rock blast holes.

Besides offering a high ROP, the COP M4 is operating gently on the bit, reducing fatigue, which adds further to its favourable total cost of ownership (TCO), Epiroc said. E-kitting is a way to further improve TCO without sacrificing productivity, the company said.

“We managed to reach the perfect balance between frequency and impact energy, which means the new hammer breaks the rock optimally – without hitting it too hard,” Gransell said.

Other benefits include a smoother and more reliable drilling process, without the hammer getting jammed in the rock, as well as low fuel consumption, Epiroc said.

It is also easy to adjust the hammer for use in different ground conditions by replacing one or two components inside the hammer.

The COP M4 is made of only eight components, meaning it is easy to assemble and disassemble. In addition, it is shorter and lighter than conventional hammers in the market, which makes it easy to handle for drill operators and their service crews, Epiroc said.

To offer best value, Epiroc is also planning to launch a new bit, specially designed for soft-rock DTH drilling.

“Launching a complete DTH solution that combines COP M4 and our upcoming soft rock bit, we’re expecting to redefine productivity and reliability in DTH soft rock drilling,” Gransell said.

Bridgestone to display world’s largest mining truck tyre at Bauma

Bridgestone says it will present a selection of its premium and innovative range of tyres, industrial products and targeted solutions developed specially for the mining and construction industries at the upcoming Bauma fair in Munich, Germany.

The company is renowned for producing premium quality tyres for everything from bicycles to aircraft, including the world’s largest mining trucks. One of these 4-m-tall tyres, the largest in the world, will be on display at the Bridgestone stand on April 8-14. It will be joined by a number of other tyres, including brand-new products:

  • VSDL Loader tyre 33/65R29 – the first wheeled-loader tyre to combine the benefits of the super-wide-base 65 series with the deep Bridgestone VSDL tread pattern. “It delivers a new level of dynamic stability and low ground pressure, while retaining the resistance to cuts and damage,” Bridgestone said, and;
  • VLTS ADT tyre – Only recently launched, this tyre was specifically developed for the 60 t ADT from Volvo Construction Equipment. “The tread is even deeper than the VLT E3 tyre, delivering truly incredible traction as well as the strength and reliability Bridgestone is famous for,” the company said.

Other tyres to be displayed will represent the highly varied range of tyres Bridgestone provides for construction machinery and construction vehicles, building-material machines, mining machines, and other construction equipment, Bridgestone said.

Bridgestone’s stand will present rubber tracks, pads, hydraulic hose, cabin and engine mounts, in addition to having technology on show that falls under the Firestone brand.

This included:

  • Firestone Airmount – This air spring is adjustable. This allows users to meet the demands of loads that range in weight by hundreds or thousands of kilos, and to maintain a level surface even as loads shift. They offer excellent vibration isolation;
  • Firestone Marsh Mellow – Marsh Mellow fabric-reinforced rubber cylinders are virtually indestructible, according to the company, do not need to be inflated with air and still protect systems from the effects of structurally transmitted vibrations. They are perfectly suited for use on equipment such as vibrating screens, acting as passive isolators at a standard beyond that of steel springs.

Bridgestone has also developed digital solutions that maximise the potential of these products, making the most of the digital technology that is being increasingly integrated into vehicles and machinery to increase productivity, decrease downtime, maximise operational potential and minimise the risks to personal safety. Part of the Total Tyre Care approach, two specific solutions will be presented at BAUMA:

  • Tirematics TPMS – The first tyre pressure monitoring system to focus primarily on fleet pressure measurements for individual machines. It stops vehicles from running on under-inflated tyres, a trend that almost all fleets are guilty of. Automated pressure checks identify what work is needed without the interruptions and downtime that result from physical checks or damage to under-inflated tyres;
  • FleetPulse – A mobile and web application designed to help fleet customers maximise the health and performance of vehicles, while improving uptime and reducing total cost of ownership and digitising operations. At the same time, FleetPulse helps in reaching the high compliance and safety standards required in the industrial world.

FleetPulse consists of vehicle checklists that the driver performs, tyre-pressure measurements performed by Tirematics technology and scheduling to resolve defects, as arranged by the Fleet or Maintenance Manager.

The data FleetPulse gathers is consolidated to offer insights into the operation of a fleet, ranging from validation of maintenance/repairs to data extraction to ensure compliance.

CrossControl to show new flat-front display computers at Bauma 2019

This year, CrossControl’s booth at the Bauma show, in Munich, (April 8-14) will showcase the latest additions to its product portfolio, including upcoming flat-front 5 in and 7 in display computers, featuring “PCAP touch interface, optically bonded screens and best-in-class sunlight readability,” the company says.

CrossControl will also highlight the next generation of small form factor displays, the CCpilot VI (pictured). This “defies expectations with its rugged 3.5 in display and robust dynamic multifunctional capabilities”, according to the company. “Use cases even include video monitoring, not something commonly achieved on such a small device,” CrossControl said.

CrossContol said: “And, the powerful get smaller as the CCpilot XM display computer series, with Intel® Atom dual core, expands with a new 9 in PCAP touch screen variant.”

Plus, CrossControl said it had reimagined the human machine interface of things into a fully-fledged platform for telematics. “Smart Connect enables connectivity between machines, displays and smart devices for additional control interfaces and to leverage supplementary communication options to enhance lean telematics,” the company said.

Enterprise Connect provides fleet-wide connectivity for geofencing, routing, data logging and diagnostics to provide end users and original equipment manufacturers (OEMs) the data they need for the next level, according to the company. “As part of this, CrossControl will introduce the new CrossLink TG, an advanced telematics module that easily integrates with on-board systems. It comes with the same modular LinX software platform as all CrossControl displays, featuring ready-made components that shorten your application engineering effort,” the company said.

CrossControl provides OEMs in the industry with industrial I/O controllers, main controllers, cable harnesses and display computers. With these components, OEMs can design modular systems, easily configured for the automation needs of different equipment types, the company said.

Herrenknecht brings boxhole backreaming to shaft sinking market

Herrenknecht expects to install one of its new boxhole backreaming machines in a mine in Asia later this year, one of the company’s Mining Project Managers, Alexander Frey, told attendees at an SME technical presentation, in Denver, Colorado, last week.

Looking to produce a system able to develop ore passes with simultaneous drilling and lining, the company has adapted boxhole boring machines it has been working on for the past nine years – which use an adapted form of the pipe jacking method – and come up with the boxhole backreaming machine.

This new machine can stabilise the shaft with thrust pipes and a steel liner, which avoids collapses of the shaft or a rework, while reducing the amount of activities in the upper level during mine development.

Herrenknecht has already built one machine and tested it at a mine in the Black Forest of Germany, Frey said. This testing saw the company sink an ore pass with a 2.8 m diameter and 22 m length at an angle of 19°. During this test work in 150 MPa Gneiss rock, Herrenknecht achieved reaming rates of up to 1.3 m/h, Frey said. According to Frey, the machine, which is equipped with a cutterhead like those employed on raiseborers, can cut really hard rock.

He added that the machines would likely be used for safely and efficiently sinking ore passes with a maximum 70 m shaft length and 3 m diameter, but it could also find other industry applications.

TAKRAF helps CBG’s bauxite expansion project hit first ore goal

TAKRAF has reported on the recent start-up of Compagnie des Bauxites de Guinée (CBG)’s Bauxite Production Expansion project in Kamsar, Guinea.

The first ore milestone at the project, which sought to increase production from 13.5 to 18.5 Mt/y, was reached on schedule, on budget and, most importantly, safely, at the end of last year.

TAKRAF, in late 2016, was awarded an engineering, procurement and construction contract worth around €100 million ($113 million) for a greenfield railcar unloading and primary crushing station, as well as a secondary crushing station and a brownfield conveyor system. The railcar unloading system was designed in collaboration with Ashton Bulk.

The scope of supply included three TAKRAF sizers, with a primary sizer in the pit beneath the tippler and two secondary sizers. These sizers, as well as the apron feeders, were designed and fabricated at Tenova TAKRAF’s Lauchhammer fabrication facility in Germany.

An important safety milestone of 1.5 million lost-time-injury-free hours was achieved on site in December 2018, according to TAKRAF.

Frank Hubrich, TAKRAF CEO, said: “We are extremely proud to be a part of this important project and of our milestone achievements. These only serve to underline the competence and commitment to our clients of our global TAKRAF organisation.

“Whether it be a greenfield or an existing brownfield operation, we work with our clients to ensure that their requirements are met on time, within budget and most importantly, safely.”

Fluor Corp acted as the engineering, procurement and construction management (EPCM) services contractor on the project, responsible for the expansion of the mine infrastructure, rail system, port facility and processing plant infrastructure and utilities.

VDMA sees revenue jump for German mining OEMs

For the first time since the crisis years, post-2013, there will be an increase in the turnover generated by the German mining equipment manufacturers this year, according to Germany’s Mechanical Engineering Industry Association (VDMA).

The VDMA expects turnover to jump around 12% to nearly €3.1 billion ($3.51 billion) in 2018, with further growth expected for the coming year, it said.

The bulk of this growth is expected to come from overseas markets, according to the VDMA.

“For German manufacturers of mining equipment, the domestic market now only plays a minor role in their business plans, with a total turnover expected to decline by 22% to €90 million in 2018,” the VDMA said.

According to Michael Schulte Strathaus, Chairman of VDMA Mining (pictured), the current policies in Germany demonstrate little affinity for the business of raw materials, and therefore mining, and are highly unlikely to provide any impetus for domestic business.

And, some 25% of exports are delivered to EU countries, a figure which has declined from the 31% achieved in 2017, with the biggest customers being Italy, Austria, Poland, France and Belgium.

Schulte Strathaus said the market is primarily marked by major infrastructure projects that will gradually be completed with no adequate replacements in sight. The VDMA, therefore, expects stagnant exports to EU countries in 2019, with a slight increase at best.

On the more positive side, the US’s share of the total export volume will increase from 15% in the past year to 17% this year, according to the VDMA.

Schulte Strathaus cited President Donald Trump’s changes to energy policies as one of the reasons for this development.

“Restrictions have been loosened, an effect which has led to an increased use of hard coal mined in the USA. This has led to considerable demand for machines that can increase productivity, and consequentially, profit; a development which benefits German manufacturers, in particular. The industry is expecting a further moderate increase in exports to the USA in the coming year,” the VDMA said.

And, German mining equipment manufacturers are also enjoying healthy business with China, with the export share to the country expected to increase to 10% this year from 7% last year. Schulte Strathaus said policymakers in China now grasped that establishing high-performance mines can only be realised to a limited extent with only domestic technology.

“German manufacturers provide technologies that are either unavailable in China or only available to a very limited degree, however, China is making considerable efforts to close existing technology gaps,” the VDMA said.

Schulte Strathaus said: “We still have an edge when it comes to extraction technology, especially in underground mining. However, we do not know how long we will be able to maintain our lead, or perhaps expand it.”

The industry expects that its exports to China will increase further over the coming year.