Tag Archives: TAKRAF

TAKRAF X-TREME sizers go the distance at Guinea bauxite mine

Three TAKRAF X-TREME class sizers supplied to a large bauxite mining operation in Guinea are, the OEM says, fully delivering on their promise of exceptional reliability and wear behaviour.

Commissioned in late 2018, the sizers had, as of the end of February 2021, crushed more than 27 Mt of bauxite ore and were still operating with their original set of wear parts.

The sizers were supplied as part of an important production expansion project at the mine. This project, awarded in late 2016 to TAKRAF as an EPC contract, encompassed a comprehensive wagon unloading, crushing and conveying system.

The TAKRAF sizers included within the overall system comprised one 3,600 t/h primary TCS-X 14.35 located in the pit beneath the wagon tippler; and two 1,800 t/h secondary TCS-X 08.30 located in the crushing building.

Both the primary and the secondary sizers are from TAKRAF’s X-TREME class sizer range. This range was developed to provide extended reliability and availability through a heavy-duty drivetrain, robust shaft and bearing assemblies, and the use of advanced wear resistant materials.

Ease of maintenance is another advantage of the TAKRAF sizer, with the primary sizer installed on site featuring a bolted tooth system to enable easy and quick replacement when sufficient wear has been experienced, the company says.

Conor Mitchell, TAKRAF Product Manager – Roll Crushers, said: “The combination of high reliability and long lifetime of wear parts means significantly higher machine uptime and that ends up translating into increased productivity for this bauxite operation. These performance levels reinforce that our X-TREME class sizer line provides maximum reliability and availability in difficult conditions, which is something the market has been calling for quite some time.”

Ukraine iron ore miner cuts electricity consumption, process water use with DELKOR thickeners

As part of its modernisation drive, a mining and processing plant recently installed 3 x 62 m diameter DELKOR high-rate thickeners with a view to reducing electricity consumption by one and a half times for the pumping of tails, as well as rationalising the use of process water.

The project concerns the design, engineering and supply of three DELKOR 62 m high-rate thickeners for the dewatering of iron ore tailings as part of the processing plant’s modernised slurry thickening complex.

This modern complex, of which construction was completed in 2020, has now done away with outdated slurry pump stations, adopting, instead, the efficient process of thickening, hydraulic transport and storage of slurries.

Employing DELKOR’s latest generation feedwell design that comes with improved flocculation together with improved flocculant and slurry kinetics, these elevated thickeners boast large feedwells, which rank as some of the largest ever built, DELKOR says.

Ramesh Mahadevan, Regional Managing Director – DELKOR, had this to say upon successful commissioning of the thickeners: “This project is a very important reference for us in Ukraine. Given current global conditions, working with a new end user is a noteworthy achievement and one for which our entire DELKOR team must be commended.”

TAKRAF, the owner of DELKOR, meanwhile, says there has been strong demand for DELKOR technology in Latin America, noting a recent order for TAKRAF Peru for the supply of 2 x 38 m paste tailings thickeners with a capacity of 455-623 t/h.

The order, placed by a Peruvian entity processing tailings from a nearby iron ore mine, forms part of an expansion to develop a second plant. This will enable the entity to handle more tailings from the mine, according to TAKRAF.

Design requirements for the thickeners include accommodating the process demands for a paste application with a target of 65% +/- 3% solids content for the underflow. This required an equipment configuration that allowed it to operate under an expected yield stress of 200 Pa in the underflow material, the company noted.

TAKRAF dry-stacked tailings test work boost for Los Andes Copper’s Vizcachitas project

Los Andes Copper says it has received additional positive results from the ongoing prefeasibility study (PFS) metallurgical test work at its Vizcachitas project in Chile.

These results show improved filtration rates for both the fine and coarse fraction tailings compared with previous testing, it said, reinforcing the decision to adopt dry-stacked tailings at the project.

An October press release regarding PFS metallurgical test work carried out by SGS demonstrated that the Vizcachitas tailings were amenable to being filtered and dry-stacked.

These same coarse and fine representative tailings samples were sent to the TAKRAF laboratories for further settling and filtration assessments. Los Andes said the TAKRAF work tested various settling and filtration parameters, including those previously tested.

The studies demonstrated that for the coarse fraction vacuum filtration, the rates improved from 1.9 t/h/sq.m to 3.4 t/h/sq.m when compared with the previous results. For the finer fraction, the settling velocities improved from 8.4 m/h to 16 m/h and the pressure filtration rates improved from 0.6 t/h/sq.m to 0.7 t/h/sq.m. The expected cake moistures for both filtration technologies were 15%.

These positive results mean that the Vizcachitas project, processing 110,000 t/d of ore, would only need to use eleven standard 162 sq.m belt filters and four 2.5 m x 2.5 m pressure filters for the tailings dewatering operation, Los Andes said, noting that other operations in the world were successfully operating with similar filter arrangements.

“Tailings filtration reduces water consumption by 50% when compared to thickened tailings disposal alternatives,” Los Andes said. “Furthermore, filtered tailings can be handled by trucks, conveyors and shovels, eliminating the need for the construction and operation of a tailings dam.

“The adoption of this technology puts the Vizcachitas project at the forefront of the environmentally responsible practices being adopted for the future of sustainable mining globally.”

ABB, TAKRAF complete commissioning of Chuquicamata conveyor system

ABB, working with TAKRAF, has completed commissioning and testing of the world’s highest-powered gearless conveyor drive system at the Codelco-owned Chuquicamata copper mine in Chile.

ABB has provided engineering design, gearless conveyor drives (GCD), electrical equipment for power supply, energy distribution and automation of a new underground and overland conveyor system at one of the world’s largest copper mines.

Chuquicamata is currently transitioning from open-pit to underground mining, with the conveyor system, commissioned in just four months, part of a new underground project that is expected to extend operations for the next 40 years.

Project management and engineering for the full electrical, control and instrumentation scope was led by ABB in Germany, with long spells on site in northern Chile to work side-by-side with TAKRAF to equip the site’s new underground operation with a large conveying system that overcomes an altitude difference of 1,200 m and covers a distance of almost 13 km, ABB said.

The three principle 11,000 t/h conveyors feature GCDs equipped with large ABB AC synchronous motors with a rated power of 5 MW each, resulting in a motor shaft torque of about 900 kNm. With every line in constant use, high availability and low maintenance are essential. Designed with a minimum of transfer stations, just one was required underground, saving significant project cost, ABB said.

Based on continuous conveying technology, the infrastructure is completely truck-less, eliminating the need for 120 large haul trucks. This results in saving around 130 million litres/y of gasoline consumption, bringing the carbon emissions from 340,000 t/y down to 100,000 t/y. It is also the first transportation system in the world to employ premium steel cable belt technology, ST10000, for use on uphill tunnel conveyors, according to ABB.

ABB high power motors in position

“This mega project achieves a number of firsts, from the system’s installed drive power to the application of the ST10000 conveyor belt,” Marc Hollinger, TAKRAF Project Manager, said. “With this project, we firmly establish TAKRAF as one of the world’s only providers capable of delivering a mega project of this nature incorporating advanced technologies that push the boundaries of what has been done before. This is a complex project of the highest magnitude demanding global cooperation between internal and external parties.”

Ulf Richter, Global Product Manager for Belt Conveyor Systems at ABB, said: “This is a new milestone in underground applications for continuous mining. It is the highest drive power ever installed on a conveyor and uses a wide range of features for data acquisition, equipment assessment and process optimisation.

“In piloting this gearless drive application with TAKRAF, we have overcome tremendous technical and logistical challenges due to underground situations, elevation change and capacity requirements.”

ABB liquid-cooled MV voltage-source frequency converters, together with large synchronous motors, deliver a decrease in active and reactive power consumption at the operation. This is highly energy efficient, and without additional network filters, it says.

ABB’s Mining Conveyor Control Program ensures smooth belt operation and safe synchronisation between high power motors and high power hydraulic brakes, necessary for secure operation of steep uphill conveyors. The drive systems also work without mechanic backstops, ABB said.

A novel embedding concept, developed jointly by TAKRAF and ABB, enables straightforward installation and alignment of the GCD motors, saving installation time and longer deployment of maintenance teams. This was considered a major benefit compared with existing GCDs in cantilevered construction, ABB said. The concept also meant motors were 100% factory assembled and tested. They can also be mechanically disconnected from the drive pulley quickly so operations can continue if drive failure occurs. The total installed drive power for the entire system, including multiple feeder conveyors, totals 58 MW, of which there are 11 x 5 MW gearless synchronous motors.

ABB has also installed ABB Ability™ Ventilation Optimizer at Chuquicamata reducing carbon emissions and providing clean air to workers in line with the strict health, safety and environment requirements.

Tenova TAKRAF passes railcar test at Guinea bauxite expansion project

Tenova TAKRAF says a 48-hour performance test for bauxite-carrying trains at a major expansion project in Guinea was successfully completed on July 1.

During the 48-hour period, starting June 29 at 00:28 and ending on July 1 at 00:28, more than 1,560 wagons, equating to 12 individual complete trains, carrying bauxite were successfully unloaded.

Compagnie des Bauxites de Guinée (CBG)’s Bauxite Production Expansion project, in Kamsar, Guinea, aims to increase bauxite exports to 18.5 Mt/y. TAKRAF, in late 2016, was awarded an engineering, procurement and construction contract worth around €100 million ($112 million) for a greenfield railcar unloading and primary crushing station, as well as a secondary crushing station and a brownfield conveyor system, at the project. The railcar unloading system was designed in collaboration with Ashton Bulk, the company said.

TAKRAF sizers, one primary and two secondary, were are also included within the crushing stations at the project, the company noted.

The bauxite expansion project hit its first ore goal back in February.

Andreas Papst, Tenova TAKRAF Senior Project Manager, said: “I would like to personally thank all colleagues, including our partners on the client’s side, for their strong willingness to collaborate and solid discipline in the successful achievement of this important milestone. TAKRAF’s successful delivery of this important project is an important reference for us in and is a true testament of our ability to operate in complex environments, overcome challenges and deliver!”

TAKRAF to focus on HPGR, technical studies and data collection at Bauma

Tenova TAKRAF says the company’s high pressure grinding roll (HPGR) technology, among other developments, will be highlighted at the upcoming Bauma fair in Munich, Germany, on April 8-14.

The company said, for the first time, show visitors will 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 HPGR on display at the booth (pictured),” the company said.

Two of these machines are being manufactured at the company’s specialised fabrication facility in Lauchhammer, Germany. These machines can each handle more than 907 t/h of cement clinker, with each machine incorporating rolls with a diameter of 1,800 mm and a weight of more than 450 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,” TAKRAF said.

The company continued: “With the integration of the well-known DELKOR and Tenova Advanced Technologies (formerly Bateman Advanced Technologies) brand of products into TAKRAF as specialised 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 and lithium recovery; as well as flotation, thickening, filtration and dry stack tailings, according to TAKRAF.

The company will also use the event to highlight its Mining Technology Centre, TAKRAF said.

“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,” the company said.

“Based upon a common understanding of the weighting of all such decision criteria, the transfer of technical and operational experience and expertise, even beyond their 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.”

TAKRAF said, 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 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.

“Utilising 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 company’s R&D agenda, TAKRAF said. “In addition, remote support solutions can also be offered.”

The company said: “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.”

The company’s stand will be located in hall C2, stand 349 at Messe München in Munich, Germany, during the event.

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.

TAKRAF designing shiploader for Chile copper expansion project

TAKRAF Italy has won a shiploader contract in Chile for an expansion project involving one of the world’s largest undeveloped copper resources, it says.

Towards the end of October, the company was awarded this “significant” contract. It followed the signing of an important agreement with a large global diversified mining company, the company said.

“[This] confirms TAKRAF Italy’s growing reputation for the supply of marine equipment in the Americas,” it added.

The shiploader in question is being designed to load copper concentrate into ocean vessels ranging from 15,000-60,000 deadweight tonnes. The equipment will be capable of luffing/slewing and will be equipped with a shuttle enabling a significant outreach, the company said, adding that the design will be executed in strict accordance with the Chile Seismic code.

Silvio Leoni, TAKRAF Italy Managing Director, said: “We are very proud of this achievement with such an important global mining customer and are fully committed to ensuring flawless execution with a view to entrenching our capabilities as a premier global supplier of port facility equipment.”

TAKRAF wins three orders from India steel, energy, cement and infrastructure group

A manufacturing group in India has selected Tenova TAKRAF to supply a slew of equipment in the country, the equipment manufacturer has said.

In the past few months, the group awarded three separate orders to TAKRAF India for the supply of equipment to the group’s operations across India. “These awards serve to boost TAKRAF’s association with an important global group and their rapid growth plans,” the company said.

The three recent projects include:

  • A combined stacker/reclaimer: As part of the proposed stockyard system for one of the group’s iron ore mines, TAKRAF is designing and supplying a stacker/bucketwheel reclaimer with a stacking and reclaiming capacity of 2,500 t/h;
  • Two large-sized portal scraper reclaimers: As a part of an integrated steel plant’s expansion plan (from 5 Mt/y to 10 Mt/y), TAKRAF is supplying and installing two large-sized portal scraper reclaimers for handling iron ore/coal/flux. The machines will travel on a 49 m rail gauge and deliver 1,800 t/h, Takraf said;
  • Two large-sized bucketwheel reclaimers: In assisting the group in expanding part of its port handling facilities, TAKRAF is supplying and installing two large-sized bucketwheel reclaimers. Each of these identical machines will handle iron ore, dolomite, coal and limestone with a peak capacity of 6,000 t/h each.

K Gopal, TAKRAF India Managing Director, said: “These projects are a testimony to the engineering design, capability and quality of the products TAKRAF is able to deliver and we look forward to working with our partners in achieving their global growth plans.”

TAKRAF sizes up competition with RMU Banovici order

Bosnia-Herzegovina-based RMU Banovici is expanding the overburden handling capacity of one of its mines by installing two semi-mobile crushing plants, each containing one TAKRAF sizer model 12.24 with a capacity of 3,000 t/h.

The order, which TAKRAF received from a consortium of Bosnian companies, comprises the supply of the sizers and basic engineering for the plant including the structure, apron feeder and discharge conveyor. The consortium will execute detailed engineering and fabrication as well as engineering and supply of the electrics locally.

The high level of involvement of local industry was a key success factor in receiving this award, formalised at a signing ceremony in Tuzla on September 11, 2018 and reported live on Bosnian TV, according to TAKRAF.

Matthias Gnilke, MD Manufacturing & Services for TAKRAF, said: “These two sizers represent another important milestone in the production of TAKRAF sizers from the TAKRAF Lauchhammer production facility and are scheduled to leave the fabrication works in mid-2019.

“A key differentiating factor of our sizers is the fact that special focus was directed towards attributes such as ease of maintenance, reduced downtime and long equipment service life already during the sizer’s initial development. As a result, our sizers offer unparalleled levels of maintenance efficiency and service life.”