Tag Archives: thyssenkrupp Industrial Solutions

Orica to install tertiary catalyst abatement tech at Kooragang Island ammonium nitrate plant

Environmental, Explosives and blasting, Mining services, Sustainable mining, , , , , , , , , ,

Orica has announced plans to install an Australia industry first tertiary catalyst abatement technology, EnviNOx®, at its Kooragang Island manufacturing plant in New South Wales.

The technology, provided by thyssenkrupp Industrial Solutions, is designed to deliver up to 95% abatement efficiency, reducing the site’s total greenhouse gas emissions by almost 50%, Orica said.

The A$37 million ($27 million) spent on the Kooragang Island Decarbonisation Project, which will help accelerate Orica’s progress towards achieving its 2030 emissions reduction target, will see proven nitrous oxide greenhouse gas (GHG) emissions tertiary abatement technology installed at its Kooragang Island plant from 2022, with commissioning in 2023, Orica said.

To facilitate the project, the New South Wales Government’s Net Zero Industry and Innovation Program will co-invest A$13.06 million, together with Orica’s A$24 million, financed by a five-year debt facility provided by the Federal Government’s Clean Energy Finance Corporation. The Clean Energy Regulator has also approved the project as eligible to generate Australian Carbon Credit Units (ACCUs).

Viewed as a long-term aid for emissions reduction in high-pressure nitric acid manufacturing plants, the tertiary catalyst abatement technology uses catalytic decomposition to destroy nitrous oxide emissions. Nitrous oxide, generated as a by-product of nitric acid production, is the primary source of GHG emissions at the Kooragang Island facility.

The technology will be installed across all three nitric acid manufacturing plants used in the production of ammonium nitrate at Kooragang Island. It is designed to eliminate at least 567,000 t/y of CO2e from the site’s operations, with expectations of reducing the site’s total emissions by 48%, while delivering a cumulative emissions reduction of at least 4.7 Mt of CO2e by 2030 based on forecast production.

Orica Managing Director and Chief Executive Officer, Sanjeev Gandhi, said: “The Kooragang Island Decarbonisation Project is a powerful example of a public-private partnership towards decarbonisation and marks a critical step in achieving our medium-term 2030 emissions reduction targets and progress towards our net zero ambition. We’re committed to working with our stakeholders to forge a pathway towards a lower carbon future together.

“Thanks to the support of the New South Wales and Federal Governments we have been able to co-invest and move forward on implementing a significant decarbonisation project.”

New South Wales Treasurer, and Minister for Energy and Environment, Matt Kean, said: “This is a great example of what can be achieved by hard-to-abate industries transitioning towards net zero emissions, under our A$750 million Net Zero Industry and Innovation Program announced earlier this year.”

Gandhi added: “The project ensures our domestic manufacturing operations remain competitive in a low carbon economy, bringing with it significant environment and regional economic and social benefits. There are also benefits for our customers, by reducing the emissions intensity of our ammonium nitrate we are in a position to offer competitive and lower carbon-intensity ammonium nitrate products, helping them to achieve their sustainability goals.

“It also allows us to look at longer-term investments in technologies, including production of hydrogen from renewable energy.”

The Kooragang Island Decarbonisation Project was approved in March 2021 by the Clean Energy Regulator to participate in Australia’s carbon market. Orica is eligible to generate ACCUs and was awarded the first optional Carbon Abatement Contract under the Facility Method for the purchase of around 3.4 million ACCUs by the Australian Government. This approach has enabled investment confidence by managing ACCU price risk, it said.

The findings from the Kooragang Island Decarbonisation Project will serve as an important Australian industry case study, demonstrating the potential for tertiary catalyst abatement technology to be deployed more widely across the sector, Orica said.

Orica has also recently partnered with the Alberta Government in Canada to commission a similar tertiary catalyst abatement technology at its Carseland ammonium nitrate manufacturing, reducing emissions by approximately 83,000 t/y of CO2e. It has also assigned approximately A$45 million over the next five years in capital to deploy similar tertiary abatement technology across its Australian ammonium nitrate sites, including its Kooragang Island site.

thyssenkrupp rail-mounted stacker handed over to BHP South Flank

Bulk handling, Mineral project development, Mining equipment, Mining services, Steel and iron ore, , , , , , , , ,

thyssenkrupp says it has handed over the world’s largest rail-mounted stacker to its client BHP for the South Flank iron ore development in Western Australia,

The first stacker among a “trio of giants”, ST-04 took more than three years of research and design development in six countries, and two years of significant local fabrication, construction and commissioning processes, thyssenkrupp said.

Over the next few months, it will gradually ramp up its operating capacity of 20,000 t/h.

The engineering company was awarded this contract − one of its largest ever fabrication and construction projects in Western Australia − by BHP back in late 2018.

Under the €150 million ($181 million) contract, thyssenkrupp was to supply two stackers that deposit iron ore into stockyards for loading, and a reclaimer for loading the ore onto trains for transport to Port Hedland. The machines’ capacity of 20,000 t/h made them the largest rail-mounted stackers and reclaimers in the world, according to the company.

Primero has been helping thyssenkrupp in this pursuit, carrying out pre-assembly of the machines at its Australian Marine Complex, in Henderson, Western Australia.

In BHP’s half year results to December 31 released earlier this week, it said South Flank remained on budget and on track to deliver first production by mid-2021. The company expects the operation to ramp up to 80 Mt/y of output, helping replace production from the existing Yandi mine, which is reaching the end of its economic life.

thyssenkrupp looks to South Africa’s depleted gold mines for renewable power developments

Environmental, Mining services, Power supply for mines, Precious metals, , , , , ,

thyssenkrupp Industrial Solutions (tkIS) has signed a memorandum of understanding with Germany’s Wismut to deliver renewable underground pumped hydroelectric energy storage (RUPHES) projects in depleted gold mines within South Africa.

The agreement builds on extensive work Professor Frank Winde undertook with a consortium including South African and other German research organisations in 2017. Prof Winde was then with the Mine Water Research Group, and now with Wismut in Germany.

tkIS, with Wismut, is now in a position to offer feasibility studies leading to full project execution for cheap reliable renewable energy. As an added benefit the revitalised mine with a RUPHES provides clean water indefinitely in water scarce regions, it said.

With industrial customers in South Africa paying R1.28/kWh ($0.08/kWh) for electricity by April 2021 and reports that of renewable energy tariffs potentially dropping to R0.40/kWh, these projects have an attractive business case, tkIS says.

The company has engaged with independent power producers and is looking to participate in the fifth independent power procurement program in the country, it says.

“Corporate customers have the option to focus on their core business and allow the IPP to invest in the RUPHES self-generation and thereby use this image-enhancing environmentally friendly and sustainable technology,” the company said.

thyssenkrupp navigates South Africa lockdown to replace platinum mine HPGR roll

Comminution of minerals, Equipment maintenance, Mineral processing, Mining consumables, Mining equipment, Mining maintenance, , , , , , ,

As the COVID-19 pandemic tightens its grip, thyssenkrupp Industrial Solutions says it is assisting customers in maintaining operational efficiencies through sustainable service delivery and innovative technologies.

“The global economic crisis, as a consequence of the COVID-19 pandemic, has put the drive for efficiency into top gear,” Philipp Nellessen, CEO of thyssenkrupp Industrial Solutions Sub Sahara Africa, said. “Fundamental to this drive is cutting-edge technology. Through our ongoing investment in people and R&D and our over 200 years of expertise, we are able to develop advanced technologies to assist mining and other industries in achieving maximum operational efficiencies.”

Although the South Africa mining industry was not operational during national lockdown Level 5, critical repairs were still permitted. As an essential service provider, thyssenkrupp has been delivering maintenance and repair as well as rebuild work to local mines.

The company assisted a platinum mine in Limpopo Province with a roll change on one of thyssenkrupp’s flagship products, a high pressure grinding roll (HPGR).

Nico Erasmus, thyssenkrupp Industrial Solutions Sub Sahara Africa Head of Service Operations, explained: “The scope of work required a rebuild on the HPGR set as well as the installation of the hardware on the mine site, making this our largest project in the national lockdown period.

“We are very pleased that even in a complete lockdown situation, we were able to complete the project in a healthy and safe manner, in excellent co-operation with our customer.”

The customer had “excellent controls” in place and thyssenkrupp complemented the risk mitigation with its own additional preventative protocols, he added.

Procedures included pre-selection of a team that falls inside the recommended age and health categories, pre-screening at both thyssenkrupp and customer sites, limiting the amount of people on shifts and in spaces, adhering to stringent hygiene measures (hand sanitising, wearing face masks, social distancing, cleaning of surfaces, tools and equipment), and implementing special transport and accommodation measures.

According to Erasmus, despite several challenges, the team adapted quickly to all the controls while still being responsive enough to get the work done safely and within the scheduled timelines.

“The transport of super loads (two trucks with 120 t loads each) was a real challenge, but our logistics team rose to the occasion and got the loads on site in no time and ready for installation,” Erasmus said.

To remain operational and continue seamless service delivery to customers, thyssenkrupp has implemented all necessary policies in line with South Africa Government COVID-19 regulations.

These include possession of all essential services permits and strict entry control protocols for employees, visitors and suppliers at all premises. Employees are required to attend mandatory training sessions conducted by the OSH department, wear all necessary personal protective equipment, sanitise regularly and maintain social distancing.

A dedicated COVID-19 committee has been set up to assess changing regulations and risks associated with office and site working environments, the company said.

“With the majority of employees working from home, we have faced our fair share of challenges but the process was very well organised with IT managing it all incredibly well ensuring that everybody was equipped in time,” Erasmus said. “We only had one day of downtime at our essential service workshop site.”

Wrapping up, an optimistic Nellessen says he is in no doubt that South Africa/Sub-Sahara Africa will recover.

“The people here are incredibly brave and innovative and companies will find their way out of the crisis,” he said.

“Despite tough times ahead for some industries, the mining sector continues to show growth and here I foresee a restart and a good recovery, depending on mining commodities probably taking anything between three to 12 months to reach previous and required pricing levels.”

thyssenkrupp helps keep BHP South Flank iron project on track

Bulk handling, Mineral project development, Mining equipment, Mining services, Steel and iron ore, , , , , , ,

thyssenkrupp Industrial Solutions (Australia) says it is on track to deliver the world’s largest rail-mounted stackers and reclaimer on schedule for BHP’s South Flank iron ore project, in the Pilbara of Western Australia.

The company was, in November 2018, awarded the contract to design, supply, construct and commission two stackers that will deposit iron ore into stockyards for loading, and a reclaimer for loading the ore into trains for transport to Port Hedland.

These large machines will each have a capacity of 20,000 t/h, making them the largest rail mounted stackers and reclaimer in the world.

thyssenkrupp developed the two fully autonomous stackers and reclaimer with the latest statutory requirements for functional safety as defined in AS4024 and AS61508. For machine collision avoidance, a combination of GPS, SIL-rated encoders and limits are used. The fully autonomous machines are digitally connected and monitored from a remote centralised control room, according to thyssenkrupp.

Offsite pre-assembly of these locally designed and manufactured machines is well underway in Perth, according to the company, with many of the large pre-assembled modules already complete. These modules are to be transported from their current location at the AMC complex in Henderson, to the BHP South Flank site with construction likely to commence in late January 2020. The first machine will be commissioned and ready for first ore in line with BHP’s 2021 target.

Zoran Matijevic, Project Director – South Flank Project at thyssenkrupp Industrial Solutions (Australia), said: “It has been a great privilege to lead thyssenkrupp’s team through design, procurement, fabrication and preassembly phases so far, and achieve 50% overall project progress milestone ahead of the plan. I look forward to logistics, construction and commissioning phases and final handover of this equipment.”

thyssenkrupp’s Industrial Solutions global Business Unit (BU) Mining has recently streamlined its operations and are now fully focusing on mining equipment, with the engineering centre of excellence for materials handling located in Perth.

Jan Lüder to replace Torsten Gerlach as CEO of thyssenkrupp mining technologies unit

Automation, Comminution of minerals, Equipment maintenance, Mining equipment, Mining people, Mining services, ,

Jan Lüder has agreed to take over as Chief Executive Officer of the Mining Technologies business unit at thyssenkrupp Industrial Solutions AG, effective November 1.

Lüder will succeed Torsten Gerlach, who is leaving the company.

Alongside his new role, Jan Lüder will remain CEO of the thyssenkrupp AG Asia Pacific Regional Headquarters and CEO of the Lead Local Office of the Industrial Solutions business area in Southeast Asia for a transition period up to June 30, 2020.

Before joining thyssenkrupp, Lüder – who has a degree in engineering – gained extensive experience in responsible management positions at various international plant engineering and
technology companies including Primetals Technologies China, Siemens Ltd China, Siemens VAI Oesterreich and Siemens AG in Germany and Malaysia.

thyssenkrupp and Northparkes collaborate on latest crushing innovation

Automation, Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, Precious metals, , , , , , , , , , , , , ,

thyssenkrupp Industrial Solutions Australia says it recently signed a contract that will see the world’s first “double-mouth” jaw-gyratory crusher supplied to China Molybdenum majority-owned Northparkes underground copper-gold mine in New South Wales.

The new crusher has been developed in consultation with Northparkes to meet its specific operating objectives, according to thyssenkrupp.

The company explained: “This unique jaw-gyratory crusher is a modern machine based on the proven BK 63-75 design. thyssenkrupp has developed a new, patented, spider to give the opportunity to feed the crusher from both sides – the “double mouth” jaw configuration, thus removing the need for a primary crusher feed (buffer) hopper and primary apron feeder.”

This dramatically reduces excavation requirements in an underground operation like Northparkes leading to a sizeable reduction in installation cost, according to thyssenkrupp.

The delivery of this latest crushing innovation follows the recent release of the company’s Eccentric Roll Crusher, the modular Variopactor impact crusher and the KB 63-130 gyratory crusher, the company said.

Northparkes is one of the most modern underground block cave mines in the world, with the majority of its loading and haulage operations carried out autonomously. Mining started up at Northparkes in November 1993, with 80% owner China Molybdenum now processing around 6.4 Mt/y of ore of high-grade copper-gold concentrate, which is shipped to its clients overseas for smelting.

Northparkes was the first mine to use the standard indirect fed Jaw Gyratory crusher type BK 63-75 for its newly developed block caving mine concept, thyssenkrupp said, with this primary crusher design becoming the “state of the art solution for block caving mines”.

Ian Smith, Engineering Superintendent of the E26L1N Block Cave Mine project at Northparkes, said: “As a long-time owner, operator and maintainer of the thyssenkrupp jaw gyratory crushers for primary crushing underground, Northparkes is pleased to be installing its third BK 63-75 in the new E26L1N block cave mine underground crusher station.

“The first BK 63-75 crusher of its kind was commissioned underground at Northparkes in 2003 followed by a second installation in 2009. Northparkes has worked closely with thyssenkrupp over the years to develop and make improvements to these crushers and has developed great confidence in the reliability and robustness of the BK 63-75 crusher.”

Smith said the first two crushers installed are of a single mouth design with the latest crusher being a double mouth design that is “ideal for our direct tip underground crushing station dump pocket that negates the use of a large run of mine bin and primary feeder thus reducing the mass excavation underground”. He said the ability of this crusher to handle a very large feed size and a high reduction ratio has also negated the need for the use of a pre-screening grizzly.

He concluded: “Northparkes’ innovative culture is again highlighted as shown in their initiation and involvement in the development of the double mouth feed shell with thyssenkrupp with the aim that the performance of this crusher will not only meet but will exceed expectations.”

thyssenkrupp to help build new Uzbekistan chemical complex, Ferkensco says

Energy minerals, Industrial minerals, Mineral processing, Mining equipment, Mining services, , , , , , , ,

A new chemical complex aimed at increasing the production of fertilisers in Uzbekistan is to be built, with help from thyssenkrupp Industrial Solutions, lead investor Ferkensco Management Ltd reports.

The construction of the new facility is in line with the Presidential Decree of April 3, 2019 on reforms in the chemical industry and making it more attractive for foreign investment, and The Presidential Decree of February 1, 2019 on the development of cooperation between the Republic of Uzbekistan and Germany, according to Ferkensco.

It is expected that the new complex will be built in the Samarkand region (pictured), on territory owned by JSC Samarkandkimyo, and that potential output at the complex will include ammonium sulphate, urea, melamine and phosphorous-based fertilisers, with the output to be used domestically, but with the option for increased exports.

“The Presidential Initiatives support increased synergies between the oil and gas and agriculture sectors, and the use of a specific quality of domestic gas for fertiliser production,” Ferkensco said, adding: “The petrochemical industry and fertilisers have an important role to play in growing Uzbekistan’s economy in the upcoming years.”

thyssenkrupp boosts Australia mining service offering with new Brisbane facility

Bulk handling, Comminution of minerals, Mining equipment, Mining services, , , , , ,

thyssenkrupp Industrial Solutions says it has opened a new service centre in Brisbane, Australia, which is ideally located to support its customer base on the East Coast of Australia as well as clients in Oceania using major logistics channels through the Queensland capital.

The facility, opened on May 14, is the result of a roughly A$1 million ($1.1 million) investment, the company said. It includes a 350 sq.m office and 1,000 sq.m of warehouse and workshop space with room for 30 employees. “The portfolio includes, among others, the warehousing and servicing of wear and spare parts, equipment refurbishments, engineering and field services and revamps,” the company said.

thyssenkrupp Industrial Solutions says it offers mining companies “tailored, cost-efficient and responsible solutions for mining, processing, handling raw materials”.

Donald Weir, CEO of the Service business unit of thyssenkrupp Industrial Solutions, said the company is continuously expanding its service offerings in these regions in order to offer the best possible service to its customers.

“Through our investment in Brisbane, we make sure that also our customers on the East Coast of Australia profit from the knowledge and experience thyssenkrupp’s global service network offers,” he said.

Andrew Howie, CEO of thyssenkrupp Industrial Solutions Australia, said the new facility enables the company to co-locate its engineering and project staff with service personnel.

“For our clients in the mining, cement and chemical industries, this means they benefit from an integrated project lifecycle approach, incorporating the latest products and technologies,” he said. “After having worked successfully with our customers in Australia for many years, this investment was a logical consequence.”

thyssenkrupp wins gyratory crusher order for Julong copper mine in China

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, , , ,

thyssenkrupp Industrial Solutions says it has won an order to supply two sets of gyratory crushers to the Julong copper mine, in China, an operation situated at an altitude of over 5,000 meters above sea level.

“Once again, it shows our solutions and engineering capabilities are able to work under the toughest environmental conditions,” the company said.

thyssenkrupp will support the second phase of the productivity expansion and reconstruction project of the mine, which is operated by Western Mining Group.

The company says it has also recently made progress on two other fronts: First, winning an order to supply two sets of bi-direction drum reclaimers to be used in a “transaction centre” of iron ore in Hebei, China, and, second, witnessing the successful delivery of steel parts for the Hesteel Laoting project.