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01

2013

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01
2013
EDUCATION
Raw materials production - Abbau fester mineralischer Rohstoffe im untertgigen Bergbau

Tudeshki, H.

Institute of Mining | TU Clausthal | Germany

TRANSFER OF TECHNOLOGY
Global Blast Borehole Technique Surface and Underground Mining with an Outlook to Future
Techniques and Mining Developments

Wennmohs, K.-H.

Liquid oxygen explosivedevelopment and application

Becker | Schwark-Werwach

Tough going for man and machine

Jautze | Passmann | Schniger

Analysis of transfer stations of belt conveyors with help of Discrete Element Method (DEM) in the
mining industry

Minkin, A.

Atlas Copco Mining and Rock Excavation Technique

Institute for New Basic-Technologies | Germany


Thyssen Schachtbau GmbH | Germany

Innovative filler removal to improve the quality of crushed sands

ContiTech Conveyor Belt Group | Mining Europe

Gschaider, H. J.
Binder+Co AG | Austria

Mining specialist BBM Maschinenfabrik Meran presents roadheader at BAUMA 2013

Operta-BBM

Thyssen Krupp: Modern gearless drive systems for high-capacity belt conveyors

Kerkhoff | Sehl | Svirsky

Mlheim an der Ruhr | Germany

ThyssenKrupp Robins Inc.| Denver | USA

NEWS & REPORTS


Metsos HRC takeshigh pressure grinding roll technology to the next level

Metso Minerals Deutschland

Sandvik Mobile Crushers and Screens unveil two new models at Bauma 2013

Sandvik Construction

Sandvik DC125R: Functional simplicity and nimble mobility

Sandvik Mining & Construction

One crusher, two configurations Sandvik s New Prisec TM CI5** Series HSI

Sandvik Construction

Sandvik: New Alpha 330 drilling tool system

Sandvik Construction

PREMIERE: First Presentation of the New REMAX 1112 MAXI to the Expert Audience!

SBM Mineral Processing GmbH

For 25 years, allmineral supplies innovative processing technology increasingly in demand


throughout the world

allmineral Aufbereitungstechnik

Global innovation in the Contractor market: New mobile jaw crusher generation from Kleemann

Kleemann GmbH

Kleemann at bauma 2013: The concentrated power of mineral processing!

Kleemann GmbH

Wirtgen: rounds out new generation of cold recyclers and soil stabilizers

Wirtgen GmbH

Wirtgen Group Mineral Technologies: Maximum reliability and economic efficiency

Wirtgen Group

Wirtgen Group introduces 29 new products at bauma 2013: Innovative Solutions for Road and
Mineral Technologies

Wirtgen Group

Bochum | Germany
Essen| Germany
Essen| Germany
Essen| Germany
Essen| Germany

Bell celebrates: 10 years of German manufacturing at BAUMA 2013!


International market introduction: E-Series takes ADTs into new era!

Oberweis | Austria

Duisburg | Germany

Gppingen | Germany
Gppingen | Germany

Windhagen | Germany
Windhagen | Germany
Windhagen | Germany

Bell Equipment Germany


Alsfeld | Germany

Bell Equipment Germany


Alsfeld | Germany

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01
2013
NEWS
& REPORTS
EDUCATION
BELL VersaTruck: Full OEM solutions for niche markets

Bell Equipment Germany

HD785-7 Rigid Dump Truck Performance and Safety

Komatsu Europe International

New Komatsu WA380-7 Wheel Loader

Komatsu Europe International

New Komatsu WA500-7 Wheel Loader

Komatsu Europe International

Komatsu Hybrid HB215LC-1 Hydraulic Excavator at bauma 2013

Komatsu Europe International

Technology for Your Success! Komatsu s Innovations at BAUMA 2013

Komatsu Europe International

Volvo Construction Equipment stands for expert knowledge at Bauma 2013

Volvo CE Deutschland GmbH

Volvo Penta at Bauma 2013: A new, exciting Start /Stop function and an update of the coming Tier 4
Final engine range

Volvo Penta

World Premiere at the 2013 Bauma: Liebherr TA 240 Articulated Dump Truck

Liebherr International AG

Liebherr is exhibiting its large IIIB-generation Wheel Loaders at the 2013 Bauma

Liebherr International AG

Liebherr exhibits revised Design of Midsize Wheel Loaders

Liebherr International AG

Liebherr introduces the 22-tonne R 922 Crawler Excavator at the 2013 Bauma

Liebherr International AG

Liebherr is exhibiting the 350-tonne R 9400 Mining Excavator at the 2013 Bauma

Liebherr International AG

LB 44 Rotary Drilling Rig completes Liebherrs Range of Products for Deep Foundation Applications

Liebherr International AG

Liebherr Components at the 2013 Bauma

Liebherr International AG

The Bauer BG range of rotary drilling rigs: The Premium Line concept

BAUER Maschinen GmbH

The Bauer Deep drilling rig RB-T 90

BAUER Maschinen GmbH

Atlas Copco: The new Boomer E - series

Atlas Copco Germany

Cut high fuel cost and increase productivity with Atlas Copcos new drill rig FlexiROC T45

Atlas Copco Germany

Alsfeld | Germany

Hanover | Germany

Hannover | Germany
Hanover | Germany
Hanover | Germany
Hanover | Germany

Ismaning | Germany

Ismaning | Germany

Biberach an der Riss | Germany


Biberach an der Riss | Germany

Biberach an der Riss | Germany


Biberach an der Riss | Germany
Biberach an der Riss | Germany
Biberach an der Riss | Germany
Biberach an der Riss | Germany

Schrobenhausen | Germany
Schrobenhausen | Germany
Essen | Germany

Essen | Germany

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BBM Operta GmbH
Continental/ContiTech
ARIA International GmbH

Sandvik
Metso
MTC

Vermeer
Wirtgen
allmineral

01
2013
NEUHEITEN
EDUCATION & REPORTAGEN
ThyssenKrupp Steel Europe expands its service network on four continents!

ThyssenKrupp Steel Europe

ThyssenKrupp Steel Europe: When the going gets tough: XAR heavy plate for mining machinery!

ThyssenKrupp Steel Europe

PHOENIX at Bauma: PHOENIX with New Monitoring System and Corrugated Sidewall Belt

PHOENIX Conveyor Belt Systems

Duisburg | Germany
Duisburg | Germany

Hamburg | Germany

Machines and systems for bulk material and piece good transport: BEUMER provides efficient
solutions for the cement industry

BEUMER Group GmbH & Co. KG

Rotor impact mills for sand processing: BHS-Sonthofen: Cubical shaped grains with round edges

BHS-Sonthofen GmbH

Processing technology: BHS-Sonthofen: Gravel processing with BHS rotor centrifugal crushers

BHS-Sonthofen GmbH

HAVER NIAGARA GmbH Member of the new HAVER & TYLER Alliance: HAVER & BOECKER
Machinery Division Muenster became HAVER NIAGARA GmbH

HAVER NIAGARA GmbH

HAVER NIAGARA F-Class Eccentric Screening Machine with New Bearing Concept

HAVER NIAGARA GmbH

HAVER NIAGARA Hydro-Clean 2000 New High Pressure Washing System with Increased Material
Throughput: Minimized water consumption and improved cleanliness of bulk mineral products

HAVER NIAGARA GmbH

HAVER-Snap-Guard Optimized Wear Protection for Screening Machines Crossbeams: Easy


maintenance and high efficiency

HAVER NIAGARA GmbH

New Holland Construction will launch new W170C Recycler wheel loader at Bauma 2013

New Holland Construction

bauma 2013: ContiTech Presents Future-Oriented Product Solutions

ContiTech AG

ContiTech at the Hannover Messe: Success with Sustainable Products

ContiTech AG

bauma INNOVATION AWARD 2013: nominees for the bauma


Innovation Award 2013!

Messe Mnchen International

EVENTS

Beckum | Germany

Sonthofen | Germany
Sonthofen | Germany
Mnster | Germany

Mnster | Germany
Mnster | Germany

Mnster | Germany

Berlin | Germany

Hanover | Germany
Hanover | Germany

Munich | Germany

The AMS-Event calender 2013

THIS MAGAZINE IS SUPPORTED BY:


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Continental/ContiTech
ARIA International GmbH

Sandvik
Metso
MTC

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NEWS & REPORTS

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www.metso-deutschland.com
Issue 01 | 2013

www.advanced-mining.com

EDUCATION

Einfhrung in die Rohstoffgewinnung

Abbau fester mineralischer Rohstoffe im


untertgigen Bergbau

Nach dem in den vorausgegangenen AMS-Ausgaben im by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki


Rahmen der Weiterbildung die Fachgebiete Rohstoffsicherung, Surface Mining and International Mining
TU Clausthal | Germany
Lagerstttenerkundung, Reservenberechnung, Geomechanik und
Hydrogeologie als Voraussetzung fr Planung von Bergbauprojekten ausfhrlich behandelt
wurde, setzt die Weiterbildung dieser Ausgabe mit der Einfhrung in die Rohstoffgewinnung
fort. Nach der Erffnung des Themas in der vergangenen Ausgabe durch die Bergbaurelevanten
Lagerstttenmerkmale werden in dieser Weiterbildung die Verfahren der Rohstoffgewinnung
im untertgigen Bergbau behandelt.

Abbauverfahren
Die Verfahren, nach denen der Abbau von festen
mineralischen Rohstoffen im Tiefbau vorgenommen
wird, sind sehr vielfltig. berspitzt kann gesagt werden,
dass die Abbauverfahren in ihrer Erscheinungsform
so vielfltig sind wie die Lagersttten selbst. Bei der
Auswahl eines Abbauverfahrens ist die Ausprgung
der Lagersttte und hier besonders die Teufenlage, die
Mchtigkeit, das Einfallen und die Standfestigkeit des
Lagersttten- und Nebengesteins der Haupteinflussfaktor.
Nur durch Abstimmung des Abbauverfahrens auf diese
Lagerstttenparameter wird ein Abbau des mineralischen
Rohstoffes wirtschaftlich und technisch mglich. Die
Abbauverfahren knnen nach verschiedenen Merkmalen
eingeteilt werden. Die Merkmale knnen in drei Ordnungen
unterteilt werden. Merkmale der ersten Ordnung sind die
Bauweise und die Dachbehandlung, Merkmale der zweiten
Ordnung umfassen Angaben ber die Verhiebsart und
-richtung. Die Merkmale der dritten Ordnung geben letztlich
Auskunft ber die Abbaufhrung und Abbaurichtung.

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Merkmale der ersten Ordnung

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Eine grundstzliche Einteilung der verschiedenen


Abbauverfahren wird mittels der Bauweise vorgenommen.
Die Bauweise beschreibt, wie ein abzubauender
Lagerstttenabschnitt in Angriff genommen wird. Die
folgenden Bauweisen sind mglich:




langfrontartige Bauweise,
stoartige Bauweise,
pfeilerartige Bauweise,
kammerartige Bauweise und
blockartige Bauweise.

Issue 01 | 2013

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Bei der langfrontartigen Bauweise wird die Lagersttte


in einer Front von bis zu mehreren hundert Metern abgebaut.
Die Abbaufront rckt dabei quer zu ihrer Erstreckung vor.
Eine solche Bauweise wird bei groflchig abgelagerten,
plattenfrmigen Lagersttten mit migem Einfallen
angewandt und ist typisch fr den Abbau von Steinkohle.

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Wird die bestehende Lagersttte in schmale Abschnitte,


so genannte Ste, eingeteilt, so wird dies als stoartige
Bauweise bezeichnet. Die einzelnen Ste weisen dabei
meist eine ein- bis dreifache Streckenbreite auf, knnen
neben-, ber- oder untereinander angeordnet werden
und werden nacheinander abgebaut. Abbauverfahren
mit stoartiger Bauweise werden meist bei gangartigen
Vorkommen des Erzbergbaus angewandt.

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Bei der pfeilerartigen Bauweise wird die Lagersttte in


Abschnitte, so genannte Pfeiler eingeteilt. Die Pfeiler werden
durch vollstndiges oder teilweises Umfahren hergestellt.
Nachdem dieses Pfeilerstreckensystem aufgefahren
wurde, kann in einem zweiten Arbeitsschritt damit
begonnen werden, die Pfeiler und damit einhergehend den
grten Teil der Lagersttte abzubauen. Die Pfeiler knnen
dabei je nach Ausprgung des Rohstoffvorkommens neben
oder bereinander liegen.
Die kammerartige Bauweise zeichnet sich durch das
Herstellen von Kammern oder rtern aus. Kammern und
rter sind gleichmig geformte Abbaurume mit einem
lang gestreckten meist rechteckigen Grundriss. Wird
der Hohlraum dabei in einem Arbeitsgang aufgefahren,
entsprechen die Abmessungen also ungefhr denen
einer Strecke, dann handelt es sich um rter. Werden
diese Abmessungen vor allem hinsichtlich der Hhe
berschritten, so spricht man von einer Kammer. Eine
Sonderform der kammerartigen Bauweise ist die so
genannte Weitung.

www.advanced-mining.com

EDUCATION
Die blockartige Bauweise ist beschrnkt auf
sehr mchtige Lagersttten. Das Vorkommen wird in
Lagerstttenabschnitte mit zum Teil betrchtlichen
Abmessungen, so genannte Blcke, unterteilt. Der
durch den Abbau geschaffene freie Raum ist bei diesem
Abbauverfahren im Gegensatz zum Kammerbau nicht
zugnglich.
Eine weitere Unterteilung der Abbauverfahren kann
durch die verschiedenen Mglichkeiten der Behandlung
der Firste whrend und nach dem Abbau vorgenommen
werden. Unter diesem auch als Dachbehandlung
bezeichneten Merkmal wird die Behandlung der
lotrecht ber dem Abbauraum anstehenden losen oder
festen Massen verstanden. Die Mglichkeiten der
Dachbehandlung sind:


der Festenbau,
der Versatzbau und
der Bruchbau.

Beim Festenbau wird das den Abbau berdeckende


Gebirge durch stehen gelassene Lagerstttenteile, so
genannte Bergfesten, dauerhaft abgesttzt. Die Festen
werden im Gegensatz zu Pfeilern nicht abgebaut.
Wird der Versatzbau angewendet, so wird den beim
Abbau entstandenen Hohlrumen durch das Einbringen
von Versatzbergen ein neues Auflager gegeben. Der
Versatz sollte eingebracht werden, bevor es zu Setzungen
des Gebirges kommt, damit eine geringe und bruchfreie
Absenkung der Deckgebirgsschichten erreicht wird.

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Merkmale zweiter Ordnung


Nachdem die Abbauverfahren durch die Merkmale
der ersten Ordnung bereits grob beschrieben wurden
erfolgt durch die Merkmale der zweiten Ordnung eine
weitere Spezifizierung. Merkmale dieser Ordnung sind die
Abbau- bzw. Verhiebsrichtung, die Verhiebsart sowie die
Abbaufhrung. Hierzu muss zunchst kurz erlutert werden,
was im bergmnnischen Sprachgebrauch unter Abbaubzw. Verhiebsrichtung zu verstehen ist. Im Gegensatz zur
Abbaurichtung, die die Richtung beschreibt, in die sich der

Issue 01 | 2013

Die Verhiebsart beschreibt in welcher Weise die


Abbaufront in Angriff genommen wird. Dies kann firstartig,
strossenartig oder stoartig geschehen.
Die Abbaufhrung schlielich umfasst mehrere
Merkmale. Sie beschreibt die rumliche Verteilung der
Abbaubetriebe im Grubengebude. Ein sehr wichtiges
Merkmal in diesem Bereich ist die Unterscheidung ob es
sich bei dem betrachteten Abbau um einen Vor- oder einen
Rckbau handelt. Bei einem Rckbau werden ausgehend
von einer Hauptstrecke zunchst die das Abbaufeld
begrenzenden Abbaustrecken aufgefahren. Im weiteren
Vorgehen wird das Wertmineral in einer rckwrts
gerichteten Bewegung in Richtung der Hauptstrecke
abgebaut. Beim Vorbau ist die Abbaurichtung von der
Hauptstrecke wegfhrend. Die Abbaustrecken knnen
dabei entweder vorher oder begleitend mit dem Abbau
aufgefahren werden.

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Als Bruchbau wird das Verfahren bezeichnet, bei dem


die Deckgebirgsschichten planmig zubruchgehen.
Durch die beim Bruch auftretende Volumenvergrerung
des Haufwerkes wird der durch den Abbau und das
Zubruchgehen entstandene Hohlraum gefllt und dient
somit den weiteren Gebirgsschichten als Auflager.
Typischerweise treten beim Bruchbau Setzungen an der
Tagesoberflche auf.

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Abbau im Groen bewegt, sagt die Verhiebsrichtung etwas


ber die Richtung des Hereingewinnens des Wertminerals
im Kleinen aus. Die Abbaurichtung beschreibt sozusagen
die Strategie des Abbaus insgesamt, whrend die
Verhiebsrichtung die Taktik vor Ort beschreibt. Sowohl
die Abbaurichtung als auch die Verhiebsrichtung kann
streichend, fallend, schwebend oder schrg realisiert
werden, wobei die schrge und fallende Richtung nur eine
untergeordnete Bedeutung hat.

Abbauverfahren mit einer langfrontartigen Bauweise


werden eingesetzt, wenn eine plattenfrmige Lagersttte
mit groer Ausdehnung vorliegt. Beispiele fr den Einsatz
dieser Bauweise sind der Abbau der deutschen Steinkohle
sowie der Golderzbergbau in Sdafrika. Von praktischer
Bedeutung bei dieser Bauweise ist heute nur noch der
Strebbau.
Beim Strebbau wird blicherweise ein rechteckiger
Flzabschnitt an einer langen Front abgebaut. Der als
Streb bezeichnete streckenfrmige Abbauraum wandert
quer zu seiner Lngserstreckung ber die fr den Abbau
vorgesehene Flche. Der Streb ist ein langer, schmaler
Abbauraum von relativ geringer Hhe, der auf der einen
Seite durch das Wertmineral und auf der Anderen
durch den Bruch bzw. Versatz begrenzt wird. Die Hhe
des Strebes ist abhngig von der Mchtigkeit des
abzubauenden mineralischen Rohstoffes. Hinsichtlich der
Dachbehandlung kann zwischen Bruchbau und Versatzbau
unterschieden werden.

www.advanced-mining.com

EDUCATION

Abb. 1:
Beispiel Strebbau [1]

diesen seltenen Fllen wird der Raum


hinter dem Streb mit taubem Gestein aus
der Kohlenaufbereitung, so genannten
Waschbergen, verfllt.

Die nachstehende Abbildung 1 zeigt den Strebbau, wie


er im deutschen Steinkohlenbergbau angewendet wird.
Ausgehend von den Hauptstrecken werden bei diesem
Abbauverfahren die obere und untere Abbaustrecke (Kopfund Bandstrecke) aufgefahren. Der Streb wird durch ein
so genanntes Aufhauen eingerichtet. Das Aufhauen legt
die Abbaufront fr den spteren Abbau frei und stellt die
Verbindung zwischen den beiden Abbaustrecken her.
Ausgehend von diesem Aufhauen bewegt sich der Streb
rechtwinkelig zu den Abbaustrecken durch die Baulnge.
Der Strebraum wird auf der rechten Seite der Abbildung
durch den bereits ausgekohlten Bereich, den Alten
Mann, begrenzt. Links des Strebraumes liegt die noch
abzubauende Kohle an.

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Um einen Wetterzug durch den Alten Mann und


damit einhergehend eine Entzndung von Restkohle zu
vermeiden werden Streckendmme errichtet. In dem in
Abbildung 1 dargestellten Beispiel wird die untere
Abbaustrecke nach dem Durchgang des Strebes
abgeworfen. Die obere Abbaustrecke hingegen wird fr
das nachfolgende Abbaufeld als untere Abbaustrecke
erneut genutzt.

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Der Bereich des Alten Mannes wird entweder mit


Versatz aufgefllt oder aber zu Bruch gehen gelassen.
Beim Strebbau ist der Bruchbau blich, nur ein geringer
Anteil der weltweit im Strebbau gewonnenen Kohle kommt
aus Streben in denen Vollversatz angewendet wird. In

Issue 01 | 2013

Ein
weiteres
Merkmal
der
Abbauverfahren mit langfrontartiger
Bauweise ist die Abbaurichtung, bei der
beim Strebbau die Richtung verstanden
wird, in die sich der Streb als Ganzes
bewegt. Im Bezug auf die Lage des
Flzes im Gebirge kann sich der Streb in
streichender, schwebender oder fallender
Richtung bewegen. Eine Auswahl von Kombinationen der
Abbau- und Verhiebsrichtungen zeigt die nachstehende
Abbildung 2.

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Die Abbaue links in der Abbildung zeigen eine


streichende Abbaurichtung mit schwebendem (oben) und
fallendem (unten) Verhieb. Die Abbildung rechts zeigt ein
Abbauverfahren mit einer schwebenden Abbaurichtung
und einem schwebendem Verhieb

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Zur weiteren Beschreibung des Abbauverfahrens


werden Aussagen zur Abbaufhrung getroffen. Ausgehend
von einem Aufhauen wird der Streb zwischen der oberen
und unteren Abbaustrecke ins Feld gefhrt. Werden die
Begleitstrecken gleichzeitig mit dem Streb aufgefahren
so wird dies als Vorbau bezeichnet. Bei einem Rckbau
werden die Begleitstrecken zunchst in ihrer gesamten
Lnge bis zur Baufeldgrenze hergestellt. An der am
weitesten von der ausgehenden Hauptstrecke liegenden
Stelle wird dann das Aufhauen hergestellt und der Streb
zurck zur Hauptstrecke gefhrt (Abbildung 3).
Die nachstehende Abbildung 4 zeigt ein Beispiel
eines langfrontartigen Abbauverfahrens wie es im
sdafrikanischen Golderzbergbau angewendet wird. Das
Golderz wird in dem als Reef bezeichneten Flz mit einer
Mchtigkeit von rund 1 Meter abgebaut. Gegenwrtig
werden in Sdafrika Teufen von 4.000 m und mehr
erreicht. Das Flz wird abgebohrt und gesprengt, das

www.advanced-mining.com

EDUCATION

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Abb. 2:
Abbau- und Verhiebsrichtungen
beim Strebbau

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Abb. 3:
Vor- und Rckbau

Issue 01 | 2013

www.advanced-mining.com

EDUCATION

Abb. 4:
Strebbau im Golderzbergbau [2]

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Abb. 5:
Golderzbergbau Mponeng Mine, Sdafrika [3]

so freigelegte Gestein wird mit Hilfe von Schrappern zur


Hauptfrdersohle gefrdert und von dort nach bertage
transportiert. Ein Charakteristikum des sdafrikanischen
Golderzbergbaus sind die Pfeiler aus geschichtetem Holz,
die die Tragfhigkeit des bereits ausgeerzten Bereiches
untersttzen.

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Stobau

Abbauverfahren mit stoartiger


Bauweise

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Die Abbauverfahren mit stoartiger Bauweise zeichnen


sich durch die Einteilung der Lagersttte in Streifen
oder Ste aus, die in flacher Lagerung nebeneinander
und in steiler Lagerung bereinander liegen. Erst wenn

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ein Sto vollstndig abgebaut ist, wird mit dem Abbau


des nachfolgenden Stoes begonnen. Die wichtigsten
Ausfhrungen dieses Abbauverfahrens sind der Stobau
und der Firstenstobau. Diese beiden Varianten werden im
Folgenden nher betrachtet.

Beim Stobau werden nacheinander mehrere


Meter breite Ste aufgefahren. Die nachstehende
Abbildung 6 zeigt anhand des Beispiels Erzbergwerk
Meggen einen Stobau bei flacher Lagerung. Ausgehend
von einer Strecke, die durch den Erzkrper aufgefahren
wird, werden zu beiden Seiten der Strecke Ste in Angriff
genommen. Nachdem ein Sto vollstndig abgebaut
wurde, wird er versetzt. Im Anschluss kann ein neuer Sto
angegriffen werden. Die Abfrderung des Erzes erfolgt
durch die mittlere Strecke.

Abb. 6:
Stobau in flacher Lagerung,
Beispiel Erzbergwerk Meggen [1]

Issue 01 | 2013

www.advanced-mining.com

10

EDUCATION

Abb. 7:
Prinzip des Strossenstobaus [Quelle:
SME Mining Engineering Handbook 2nd
Edition Volume 2, 1992]

Auch bei steiler Lagerung kann der Stobau eingesetzt


werden. Diese besondere Art des Stobaus wird als
abwrts gefhrter Stobau oder als Strossenstobau
bezeichnet (Abbildung 7).
Hierbei werden die einzelnen Ste nicht nebeneinander
sondern untereinander aufgefahren. Ausgehend von
einer Wendelstrecke oder Rampe wird eine Strecke im
Erzkrper aufgefahren. Im Erzkrper wird zudem ein
Rollloch aufgefahren, durch das das Erz auf die tiefer
gelegene Frdersohle verstrzt werden kann. Ist ein Sto
vollstndig abgebaut, wird er versetzt und dient dem
darunter zu gewinnenden Sto als Firste . Der Versatz
wird durch einen im Versatz mitgefhrten Verschlag bis
auf die zu versetzende Stelle transportiert. Allerdings gilt
das Verfahren als verhltnismig leistungsschwach und
teuer. Aus diesem Grund kommt es nur noch selten zum
Einsatz.

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Issue 01 | 2013

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Firstenstobau

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g

Der Firstenstobau kann bei steilstehenden


Erzlagersttten eingesetzt werden. Ausgehend von
einer Wendelstrecke (Abbildung 8) wird im Rahmen der
Vorrichtung zunchst eine Gangstrecke aufgefahren, die
den Erzkrper in seiner gesamten Mchtigkeit unterfhrt.
Die Gangstrecke ist meist durch eine Schwebe, das
heit durch einen stehen gelassenen horizontalen
Lagerstttenstreifen, von der Frderstrecke getrennt.
Ausgehend von der Gangstrecke bzw. von der nchst
hher gelegenen Sohle werden vertikale Rolllcher fr das
Erz und den Versatz erstellt.

n
i
m

o
c

Abb. 8:
Prinzip des Firstenstobaus [1]

www.advanced-mining.com

11

EDUCATION

n
o
o

s
g

n
o

l
s
n

i
t
a

Aus der Gangstrecke bzw. aus einem vorher erstellten


berbruch wird ein gerader Firstensto mit einer Hhe von
bis zu 4 m aufgefahren. Dies geschieht mittels Bohr- und
Sprengarbeit. Ist dieser Sto abgebaut kann er versetzt
werden und dient als Arbeitsebene fr die Gewinnung
des darber liegenden Stoes. So wird ein Sto nach dem
anderen angegriffen, bis die nchst hhere Sohle erreicht
ist. Als Versatzarten kommen Spl-, Pump-, Sturz-, Blasoder Schleuderversatz in Betracht.

a
r
T

Eine Sonderform des Firstenstobaus ist der so genannte


Magazinbau. Das Verfahren ist nur bei sehr standfestem
Nebengestein und einer regelmigen Ausbildung der
Lagersttte anwendbar. Der Abbau funktioniert prinzipiell
wie beim Firstenstobau, allerdings dient hier das bereits
gesprengte Haufwerk als Arbeitsebene fr den Angriff
des nchsten Stoes (Abbildung 9). Da das gesprengte

Issue 01 | 2013

n
i
m

o
c

Abb. 9:
Magazinbau [2]

und damit aufgelockerte Gestein mehr Raum in Anspruch


nimmt als das anstehende Gestein, muss ein Teil des
Erzes durch Trichter auf die Frdersohle abgezogen
werden. Es muss stets soviel Haufwerk abgezogen
werden, dass ein ausreichend groer Arbeitsraum im
Bereich des Firstenstoes entsteht. Das Verfahren ist
sehr leistungsfhig, allerdings ist ein groer Teil des
verkaufsfhigen Wertminerals auf lngere Zeit im Speicher
gebunden. Zudem ist das Verfahren nicht anwendbar,
wenn das Material, wie bei einigen sulfidischen Mineralen
der Fall, zur Selbstentzndung neigt oder wenn eine
Vernderung des Speichergutes beispielsweise durch
Oxidation auftritt, die eine Aufbereitung mglicherweise
erschwert.

www.advanced-mining.com

12

EDUCATION
Bibliography

[22] Thyssen-Schachtbau: Thyssenschachtbau-Report 2004

[1]

Reuther, E.-U.: Lehrbuch der Bergbaukunde

[2]

Atlas Copco: Underground Mining Methods Mining


Methods case studies, a technical reference edition,

[3]

Fotomaterial:
http://web.uct.ac.za/depts/geolsci/dlr/hons2000/

[4]

Bundesanstalt fr Geowissenschaften und Rohstoffe:


Verschiedene Artikel und Publikationen

[5]

GibGas Fahren mit Erdgas: Internetprsenz


http://www.gibgas.de/german/fakten/naturstoff_erdgas.html

[6]

Bay. Sand- und Kiesindustrie: Schriftenreihe der


bayrischen Sand- und Kiesindustrie, Heft 2

[7]

Bundesanstalt fr Geowissenschaften und Rohstoffe: Dr.


Michael Kosinowski, Tendenzen auf dem Rohstoffmarkteine Analyse der BGR

[8]

Deutsches nationales Komitee des Weltenergierates:


Energie fr Germany Fakten, Perspektiven und
Positionen im globalen Kontext 2002

[9]

DEBRIV: Arbeitsgemeinschaft Energiebilanzen 2003

[10] World of Mining Surface and Underground: Die


Verfgbarkeit von Rohstoffen insbesondere von fossilen
Energietrgern, 04/2004
[11] Verein der Kohlenimporteure: Jahresbericht 2003
[12] Bundesanstalt fr Geowissenschaften und Rohstoffe:
Rohstoffwirtschaftliche Studie, 2002
[13] DEBRIV: http://www.debriv.de/zahlen/folien/grafik09.pdf
[14] Statistik der Kohlenwirtschaft e.V.:
http://www.kohlenstatistik.de/ftp/BK-WELT.XLS
[15] Wirtschaftsvereinigung Bergbau: Nachfrage und Absatz
von Steinkohle, http://www.wv-bergbau.de/
[16] USGS United States Geological Survey: Iron Ore
Statistics and Information, Mineral Commodity Summaries
2005
[17] International Aluminium Institute: Aluminium production www.world-aluminium.org/ production/
[18] Wirtschaftsvereinigung Metalle: Metallstatistik 2003

[23] Thyssen-Schachtbau: TS Schachtbau und Bohren,


Internetprsenz http://www.schachtbau-bergbau.de/
[24] RKK-Soilfreeze Technology: About Ground Freezing,
www.cryocell.com/AboutGF.html
[25] Deilmann-Haniel: Herstellung einer Wetterbohrung auf
der Schachtanlage Heinrich Robert, Zeitschrift Unserer
Betrieb, April 1992,
[26] Herrenknecht: Datenblatt VSM 8000 Shaft sinking machine
11/2004
[27] Orica: Internetprsenz der Firma Orica,
http://www.oricaminingservices.com
[28] DBT: Internetprsenz der Firma DBT, www.dbt.de,
Broschre DBT Diesel FBR-15 Coal Hauler
[29] Atlas Copco: Internetprsenz der Firma Atlas Copco,
Photoarchiv, http://www.atlascopco.com
[30] Kali und Salz: Internetprsenz der Firma K+S, Pressefotos,
http://www.k-plus-s.com
[31] Deutsche Steinkohle AG: Internetprsenz der Firma DSK,
Bildarchiv http://www.deutsche-steinkohle.de
[32] Betek: Internetprsenz der Firma Betek
http://www.betek.de/
[33] Eickhoff: Bildmaterial der Firma Eikhoff Bergbautechnik
GmbH
[34] Wirth: Internetprsenz der Firma Wirt,
http://www.wirth-europe.com, Broschre RM T 1.24
[35] Parallelgraphics: Bildmaterial der Firma Parallelgraphics,
http://www.parallelgraphics.com
[36] Voest Alpine Bergtechnik: Internetprsenz der Firma Voest
Alpine Bergtechnik http://www.vab.sandvik.com,
Bildmaterial ASVA
[37] Herrenknecht: Internetprsenz der Firma Herrenknecht
http://www.herrenknecht.com
[38] Geo Kompakt: Geo Kompakt, Nr. 1, 2004, Die Geburt der
Erde, Vom Werden und Vergehen der Gesteine, S. 89
[39] Steinkohle-Portal: Internetprsenz
http://www.steinkohle-portal.de

[19] Volker Lukas: Kali- und Steinsalz in Germany,


Akademie der Geowissenschaften, Hannover, 2002,
Verffentlichung 20, (2002), S. 54-62

[40] DBT: Internetprsenz der Firma DBT, www.dbt.de

[20] IG BCE: Bericht I/2004, Kalibergbau und weiterer


Nichtkohlenbergbau

[42] Mining Magazine: Mining Magazine, Ausgabe Februar


2005 http://www.grundwasser-online.de

[21] Deilmann-Haniel: Internetprsenz der Firma DeilmannHaniel, http://www.dh-ms.com

[41] Halbach & Braun: Internetprsenz der Firma Halbach und


Braun, http://www.halbach-braun.de/

Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki studied from 1977 to 1980 at the Mining College of Shahrud (Iran);
following several years of work in the mining industry, he completed his mining study at the RWTH Aachen in 1989.
Since 1992 he was Chief Engineer at the Institute for Surface Mining (Bergbaukunde III) of the RWTH Aachen, mainly active in the field of open cast mining and drilling technique. He did his doctor degree in 1993 and qualified as a
university lecture in 1997. In 1998 the Venia Legendi was awarded to him be the RWTH Aachen for the field Rock
and Earth Open Pit Mining. In November 2001 he was appointed as Professor for Surface Mining and International
Mining at Clausthal University of Technology.
He already has over 25 years of experience in the field of project planning and cost-benefit analysis within the frame
of various mine planning projects. The international tasks rendered by him mount up to more than 300 international
raw material-related projects.
| tudeshki@tu-clausthal.de | www.bergbau.tu-clausthal.de |

Issue 01 | 2013

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13

NEWS & REPORTS


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TRANSFER OF TECHNOLOGY

Global Blast Borehole Technique

Surface and Underground Mining


with an Outlook to Future Techniques
and Mining Developments

Dipl.-Ing. Karl-Heinz Wennmohs


Atlas Copco |
Mining and Rock Excavation Technique |
Essen | Germany

Blasting and drilling engineering has proven to be one of the most effective and safe loosening
techniques in global surface and underground mining. However, it should be noted that this
statement does not refer to mining operations with geological conditions that allow for
application of economic, mechanical loosening techniques.

Blast Borehole Technique Underground


The 30 kW impact performance limit for hydraulic drill
hammers in underground small bore drilling (38 -64 mm)
was considerably increased through the launching of a
40 kW hydraulic drill hammer during the 2012 Las Vegas
exhibition. With todays drilling tool standards, such
performance boosts are only possible through an increase
of blow rate. The reasons are clear limits to the resilience
of drilling tools, with regard to the maximum load through
single impact energy. This new generation of hydraulic
drill hammers with more than 100 Hz blow rate requires
highest precision in control of the hammer mechanism and
in production of the components.

Fig. 1:
Development of Impact Performance
in Hydraulic Drill Hammers

Issue 01 | 2013

Controlling such extraordinary high impact performance


is only possible with a highly developed computer system,
since reaction times for influence on drill parameters are
extremely small, due to the high drilling speed. Furthermore,
in relation to the progress of drilling, the drilling fluid has to
be adapted to the conditions of the cuttings according to
pressure and volume. This performance class is primarily
applied to 2-4 armed drilling jumbos, which are operated
according to requirement profiles of automatic operations
for mechanical pre-drilling and injection drilling of up
to approximately 30 m. This drilling technique status in
hydraulic drilling hammers for small bore drilling will
remain for a few years, but further developments can be
expected.

Development of Impact Performance in


Hydraulic Drill Hammers

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15

TRANSFER OF TECHNOLOGY
Fig. 2:
Four-armed drilling jumbo Boomer XE 4
with COP 4038 drilling hammers

Up to now, this design size of drill jumbos has been


designated for classical tunnel driving. However, with the
extension of mines and the increase in diameters, twoand three-armed drill jumbos are increasingly being used
in excavations. Typical examples are tunnels and drifts for
the underground excavation in the Chuquicamata mine,
north of Chile.

Fig. 3:
Drilling equipment for
underground extraction
drilling

In the year 2000, with high-performance hydraulic drill


hammers with 40 kW impact energy, the production drilling
equipment developments for underground long hole drilling
were already advanced.
Compared to drill hammers for small bore drilling,
this drill hammer class has completely different impact
characteristics. In these applications, considerably bigger
and stronger drill rods are applied in connection with other
borehole diameters (76 -140 mm). These drill hammers have
substantially higher single impact energy, and the impact
frequency is considerably lower. It is for this reason that
the dimensions and weight of the main piston are basically
larger. Such are important drilling parameters for long hole
drilling.
Apart from classical top-drill hammers, down-thehole hammers are increasingly being used in large-scale
operations. The reason is bigger bore hole diameters and
the comparatively long boreholes. It is possible that there
are limits for the transfer of impact energy for the top
hammer drilling with these conditions.

Issue 01 | 2013

www.advanced-mining.com

16

TRANSFER OF TECHNOLOGY
Fig. 4:
Extraction drilling device with water-driven
down-the-hole hammers

These down the hole hammers are operated with


compressed air or water. In compressed air application,
high-performance compressors are used, which increase
the available air chucking from 5 bar to 20 -25 bar. In order
to reduce the dust generation, these devices are operated
with an air-water mix. In terms of energy efficiency,
water-operated down-the-hole hammers are powerful

and much more economical than if they are operated


with pressurized air,. However, the operation with water
requires an underground infrastructure, which allows for
such volumes and quality of water. A typical utilization of
this technique can be seen in the LKAB in north Sweden
Kiruna.

Fig 5:
Detecting and drilling
through dislocations

Issue 01 | 2013

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17

TRANSFER OF TECHNOLOGY
Modern long-hole drilling devices for underground
extraction offer all possibilities for control and can generate
a complete wheel of bore holes, up to a borehole length
of 50m, either fully automatic or through remote control.
Since, according to the rocks to be drilled, such borehole
lengths call for a change of drill bits, these devices with
top drill hammers offer the possibility of automatic drill bit
change. The drill bit magazine on the drilling device makes
this possible. This magazine can carry 9 drill bits with a
diameter of 115 mm. Based on the parameters given, a
modern drilling device control selects the time of changing
the drill bit. This is critical for the drilling progress, but
also an important step towards optimizing costs of drilling
devices, since it prevents over-drilling of drill bits. In order
to ensure that high-performance drilling devices can drill
securely and appropriately, they have to be able to timely
detect and react to irregularity in mountains, e.g cavities or
areas with very soft formations.
This technique ensures that, upon reaching such
a zone, the drill hammers automatically are put into a
reduced impact performance mode, and unnecessary
empty strokes are avoided. After drilling through this zone,
the system recognizes the situation, and the drilling device
continues to work at full force.

Drilling borehole technique above ground


The mining in open pit mines through loosening and
crushing begins with modern drilling devices. In formations
of over 100 MPa rock compression strength, these are
devices with percussion drilling methods like top-drill
hammers and down-the-hole hammers. Exceptions
are open pit mines with borehole diameters between
180 mm and 406 mm. If the rock parameters of approx..
80 200 MPa compression strength allow for it, rotational
drilling methods with rotary bits are applied. In higher
compression strengths, which can be above 300 MPa,
modern down-the-hole hammers are applied. It should be
noted that transition between rotary drilling technique with
rotary bits and the percussion drilling is fluid and is dealt
with differently.
Large open pit mines with annual outputs of
60 -100 million tons possess modern drilling tools, which
can often operate without extension drill rods in bench
heights of up to 18 m. This drilling technique, which
is internationally called single pass drilling, reveals
high gross drilling outputs and allows for automations, if
needed.

Fig. 6:
Rotary drilling DM for borehole
diameters of 203 305 mm

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY
Nowadays, drilling devices for diameters of 51 178 mm
are the drills mostly used in quarries and they work with
top- or down-the-hole hammers. The impact performance
of top drill hammers in this machine sizes lies in a spectrum
between 20 and 40 kW. Modern down-the-hole hammers
of this class, with an operation pressure of 30 bar, have a
comparable impact performance of 40 kW and above on
the borehole bottom. Drilling devices in weight categories
of up to 25 tons are used in open pit mines with an annual
production of up to 10 million tons, or in large operations
for special drilling tasks, which cannot be covered by
large-scale drilling equipment. This so-called large-scale
drilling equipment are design sizes with machine weights
of up to 200 tons.
This is understandable, since it is necessary to specify
respective pressure values on the drill string, without
changing the position of the drilling device. When applying
rotary drilling technique, in which mostly rotary bits are
applied, large amounts of cleaning air are needed to convey
the cuttings from the borehole bottom to the borehole
top with high speed. In order to do so, compressors are
installed on these drilling devices. They have a delivery
quantity of up to 105 m3/min, with an operation pressure
of 7.5 bar. With this technical fitting the installed motor
performance on the drilling devices is 1200 kW. This can
be either a diesel engine or an electrical engine.

Example of a typical open pit mine in


hard rock
The Boddington open pit mine of the Newmont Company,
in which gold and copper are mined, is located in west
Australia, close to Perth.
Its geology consists mainly of andesite and diorite, with
a specific density of 2.8 tons/m3, and uniaxial compression
strength of 250 MPa. In addition, there is dolerite with a
specific density of 3.0 tons/ m and compression strength of
> 300 MPa. These geological data naturally have influences
the drilling engineering during mining. All drilling devices
are equipped with rotating hammer drills, which mainly are
down-the-hole hammers. Mining extends over two open
pit mines, which are connected to each other.
The bench height is 12 m, the borehole diameter for the
extraction drilling boreholes is 216 mm. Smaller borehole
diameters are only selected for border areas (slopes). The
drilling pattern, which based on geological conditions, was
developed in a way to produce a rock pile with smallest
possible fragments, in order to use the cost benefits of
blasting engineering, compared to crusher engineering.

In the areas where due to geology, rock strength and


quartz content rotary drilling technique reaches economical
limits, these drilling devices are used with down-the-hole
hammers in diameters between 193 and 269 mm. For such
applications the drills are equipped with high-pressure
compressors with delivery quantities of up to 41 m3/min
at 24 bar. The exhaust of the down-the-hole hammers is
utilized as drilling air. The motors in these type series have
560 kW and are electric or diesel-powered. An important
step in development of drilling engineering is the so-called
PARD-Method. PARD stands for percussion assisted
rotary drilling. This technique consists of a standard rotary
drill bit, with a down-the-hole hammer, which strikes a socalled soft stroke on the drill bit with the low air pressure
(7.5 bar) of the drill air. The combination of these systems
presents astonishing results. The following results show
an example. In an open pit mine in South America , with
a rock compression strength of 200 250 MPa, borehole
depth 16.5 m, boring time with rotary drilling approx..
60 min/borehole. The combination of rotary drilling
technique and down-the-hole hammer reduced the time
by 50%.

Fig. 7:
7 PARD = Percussion Assisted Rotary Drilling

Issue 01 | 2013

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19

TRANSFER OF TECHNOLOGY

Fig. 8:
Boddington open pit mine of the Newmont Company in Australia

The extraction from this operation is approximately 100


million tons per year. Currently 18 drills, including equipment
of subcontractors, are operating around the clock.
100,000 meter drilled per month is needed for production.
This can be achieved with a gross drilling performance of
22.5 meters drilled per hour for production drillings of
216 mm borehole diameter.

Approximately 1,000 km of drifts are needed for preparing


the actual mining. An economic operation of such deposits
with decreasing metal contents is only possible through
conveying of large masses. The projections show a
reduction of copper contents in the deposits. The positive
characteristic of Chuquicamata is the share of molybdenum
in raw ore.

The mining of approximately 100 million tons produces


roughly 100 tons of gold and an interesting amount of
copper (Source Newmont)

This mining method requires high investments in


development and equipment. The under-cut and the
production areas require a considerable number of drifts.
In order to start mining in 2018, four production levels are
excavated, which ensure mining of 340,000 tons of copper
per year. Once the digging is completed and the block cave
is in operation, mining costs are very low, as there is only
loading and conveying. The classical drilling and blasting
is only applied for crushing of large ore rocks at loading
points, when mechanical bolder equipment fails.

Planned Large Mines


The current situation in the commodity industry leads
globally active mining companies to large investments in
brownfield and greenfield projects. Therefore, extensive
mining projects are being implemented or planned in
mining regions. Examples are projects in Mongolia, project
Oyu Tolgoi and in Chile.
The open pit mine Chuquicamata in Chile is being
developed into an underground mining. This open pit mine
is currently the largest copper open pit mine in the world,
with an annual production of approximately 440,000 tons
copper per year. This means that this mass open pit mine
will be converted into the worlds largest underground
mine ever operated. In the course of conversion the open
pit mine is crossed underground with tunnels and drifts
and consecutively operated as a typical mass mine with
the block caving mining method.

Issue 01 | 2013

Mining is concentrated on a level stripping of the ore


body at the numerous loading points, as well as on avoiding
cavities within the mining area. The operating equipment is
construed for a daily conveyance of 150,000 to 200,000 tons.
Since such conveyance can hardly be done vertically, it is
done by belt conveyance. The excavations have started
in 2012. Various internationally renowned companies
conduct the excavations for ventilation-, transport- and
access tunnels and the underground exploratory work of
the open pit mine. This work is planned to be completed
within the next years, until the start operation is taken up,
and the underground mining is to start in 2018.

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20

TRANSFER OF TECHNOLOGY

Fig. 9:
Developed mining with bock caving

Outlook
Future mining operations, which are developed from
open pit mines or as greenfield projects, increasingly are
planning their work with the bock caving mining method,
in order to achieve their high production goals. However,
this technique presumes specific mountain parameters.
In case these are not met, known mining methods are to
be applied, which can be modified based on the available
machine- and blasting agent technique.
In these large mines, automation possibilities should
increasingly be used, particularly in the areas of drilling
engineering and conveyance. This includes involvement of
the entire equipment in a computer network, which allows
for remote control and access to equipment functions
in case of interruptions. The connection can help to use
recorded data of the drillings, as well as borehole position
and length for consecutive blasting. The search for
suitable personnel is more and more becoming a key issue
for mining companies. Jobs in mining have to offer more
than financial incentives, they have to be attractive and to
attract the future generation. Among these attractions are
trainings with simulators (drilling, loading, conveying).

Issue 01 | 2013

Automation is the key in open pit and underground


mining. The rationale for this need lies in the abovementioned problem, which is finding personnel for open pit
and underground mining. But another key argument is the
possibility of a higher utilization of machines. The matching
of drilling and blasting engineering with the goal of optimal
fragmentation of the excavated material will have a central
position in the cost-structure of mining. Therefore more
interaction of drilling and blasting engineering is needed in
the future. There is a high potential for development in the
overall area of mining.
In medium-term, mechanical loosening techniques will
be a serious competitor for drilling and blasting engineering.
This is not only due to safety issues with regard to handling
explosives, but also due to the discontinuous operation
of drilling and blasting engineering. Currently there are
extensive global efforts to develop a continuous cycle in
the advance technique, through the application of new
methods in mechanical loosening technique.

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21

TRANSFER OF TECHNOLOGY
Fig. 10:
Networking of Equipment

These new technologies will be applicable to all


geologies encountered. It could be a possible solution,
particularly in mining in extreme depths of 5,000 m and
above, as the dangerous and difficult working conditions
in these depths pose great challenges due to the increase
in rock bursts.
In the coming years the available drilling technique for
open pit and underground mines, combined with blasting
means, will not loose much of its market shares. Mechanical
loosening techniques with all their advantages in operation
will have to prove cost-effective. This is exactly why there
is a potential for advancements in modern drilling and
blasting engineering in future years.

Issue 01 | 2013

Dipl.-Ing. Karl-Heinz Wennmohs


Atlas Copco Mining and Rock
Excavation Technique
Langemarckstrasse 35
D-45141 Essen

FOR MORE INFORMATION AND CONTACT:


| karl-heinz.wennmohs@de.atlascopco.com |
| www.atlascopco.com |

www.advanced-mining.com

22

TRANSFER OF TECHNOLOGY

Liquid oxygen explosive

development and application

by Dr. rer. nat. C. Becker |


Dr.-Ing. B. Schwark-Werwach |
Institute for New Basic-Technologies (INBT) |
Nordhausen | Germany

During the 17th BUS- Congress, the two authors of this paper have made two separate
presentations on the characteristics (1) of the PMMA-LOX-Ex system and the resulting automated
applications with regard to blasting (2). During the past two years many new studies have been
conducted on the PMMA-LOX-Ex system, as well as studies on further applications of the system
in various areas of blasting , such as special blasting and extraction blasting.

In summary, these are:


1. Operation of blasting equipment that allows for being
furnished with up to 25 kg of LOX-Ex
2. Determining further blasting parameters and outputs of
the PMMA-LOX-Ex system.
3. Implementing various simulated blastings.
4. a) Plating and b) impacting of conventionally nonweldable metals through blasting.
5. Successful multiple shelling with LOX-Ex-capsules on
gypsum and greywacke rocks, according to the LOX-Exmethod (2) introduced in 2011.
6. First successful test on the basis of the Imloch-blasthole
method.
7. First successful developments and testing of LOX-Exfuses.

Operating blasting equipment of up to


25 kg LOX-Ex
This is manually operated equipment that pre-cools fuel
and containers of explosives and doses initial amounts,
mixes and stores them in Thermo- storage boxes. The
centrepiece is the pre-cooler for the molecularly structured
nano-particle-fuel, seen in fig 1. The central cylindrical
space, which is equipped with a mixing shaft, serves for
the collection of fuel.
It is enclosed by a double-walled barrel, which is filled
with the cooling medium, that is liquid nitrogen or oxygen.
After 1.5 to 4 hours - based on the amount of cooling liquid
and intensity of stirring- the fuel is cooled to a temperature
of approximately 160C, which is sufficient for a dust-free
mixture.

The INBT would like to thank the


following companies and institutes for
their support and collaboration in reaching
these development milestones: BAUER
Maschinen GmbH, Perforator GmbH,
Knauf German Gypsum Works KG, ISAF TU
Clausthal, KANEKA Corporation, SFL Water
Power Plants GmbH and the BAM.

Fig. 1:
Pre-cooler (right), LOXEx- storage box (left)

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY
In a thermos container, shown in figure 1, the material
needed for the application are weighed in, mixed with the
LOX and kept until usage.

Further blasting parameters and outputs


The LOX-Ex is a liquid oxygen- fuel system, in which the
fine structure of the fuel is specifically used to influence
parameters such as blasting speed. The composition of
the explosive, the system PMMA-LOX-Ex, can be adapted
to respective tasks. As such it is possible to optimize the
quality of the blasted rock.
Following parameters can be pre-set in advance:
a) Load intensity
b) Speed of detonation from approx. 1000 m/s to
over 9000 m/s
c) Volume of fumes and
d) Blasting dynamics or smashing power.
On a): Like with all explosive agents, this is determined
by simple specification of quantities, immediately
before application.
On b): NIn addition to patented methods, the
granulation or compaction (specific cluster forming)
of the molecularly structured nano-particle fuel is the
determining factor for this target parameter.
On c): the volume of fumes, which are generated
during chemical reaction of the blasting agent, can
be set by a dosage of LOX or by addition of water in
appropriate physical modification.
On d): The blasting dynamics of the explosive can
be optimized through integration of chemically inert
material and spacing or shaping elements at the
load.

Many video documentations (6) of free blasting tests


show that in the moment of chemical reaction the fire
ball (reaction plasma) lights up well visibly and big in
size, according to the energy content of approx. 9 MJ/kg.
The view can only occasionally be obstructed by raised
dust. Contrary to many conventional blasting agents
that are construed to gas and fume generation, this
reaction plasma that passes into the gas phase has its
own extensive and short-term thermodynamic energy
content. This potential can be extended for a few ms and
shifted through addition of long-term fume generators, at
the expense of the fireball power.

Conducting various simulated extraction


blastings
Three simulated extraction blastings were conducted in
the years 2011 and 2012. The first two test were qualitative
ones, and it was only the third test which aimed at a
quantitative result regarding the break-off amount per
each kg of explosive.

Test 1: Borehole blasting


This test was conducted in a vertical borehole of a depth
of 4m and a diameter of 90 mm, with a distance of approx.
3 m to the rock edge in the gypsum rock. An insertion
slot consisting of PP is inserted over the entire borehole
length. The upper meter of the inserted tube was designed
in a way, that it could be removed after inserting the load.
This tube was filled with 12 kg LOX-Ex (i.e. 4kg/m) from the
borehole depth up to 1 m below the surface, and insulated
on the top with snow and ice (since it was a winter day)
and ignited with a commercially available instantaneous
fuse. The result of the blasting left nothing to be desired.

Further parameters are:


Smallest column charge tested in 2011 was 14 mm. In


the upscaled comparison of tested column charges of
70 mm no losses in break-off amounts and quality of
blasted rock could be seen.
Tests have shown that, based on rock type, 85 to
100 g PMMA-LOX-Ex, applied with insultation, break off
approximately 1 ton of rocks.
In case both components of the PMMA-LOX-Ex (i.e the
PMMA fuel and liquid oxygen) are applied in pure form
and in correct relation of composition, no toxic nitrogen
oxides occur, only H2O and CO2.

Issue 01 | 2013

Test 2: Mini blasting


The aim of the test was,

To check whether charge columns with very small


diameters entail output losses

And to determine, how the blasting performance and


grain composition changes with the design size, as
well as to develop a basic concept of the automated
and low-vibration continuous extraction blastings with
regard to feasibility.

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24

TRANSFER OF TECHNOLOGY
6 Boreholes of 28 cm depth and 20 mm in diameter
were drilled into the anhydride soil in two lines and with
a distance of 45 to 50 cm, vertical to a brim. PE tubes
with an internal diameter of 14 mm were inserted into
the boreholes, which were each filled with approx. 38 g
PMMA-LOX-Ex, furnished with an electrical detonating
cap, insulated and ignited. The holes directly facing the
brim were furnished with instantaneous fuses and the
second row was furnished with fuses with 25 ms delay. Due
to some mishaps during precooling of the insertion slots
and fuses it was only possible to fill and ignite 4 holes
instead of 6. In addition the terrace was neatly blasted off
and it was proven that charge columns with diameters of
14 mm can ignite and blast without output losses.

Figure 3 shows the image sequence from high-speed


video-taping of the pit blasting, picture 4 shows the
excavated pit.

Table. 1:
Blasting results of a pit blasting operation

Length of blasting pit approx.


Width of blasting pit approx.
Depth of blasting pit approx.

3,9 m
3,2 m
2,6 m

Density of gypsum rock

2 t/m

Volume of rocks

30 m

Amount of rocks
Amount of explosive

60 t
5 kg

Test 3: : Rock Pothole blasting

Specific baring/heading

6 m/kg

Weight ratio rock/PMMA-LOX-Ex

12 t/kg

For future tests it was planned


to create a blasted cavity in the
closed gypsum- bedrock.

Explosive requirement

ca. 84 g/t

Table
1
contains
all
quantifiable specifications for
this test.
And the most important result is
that, based on type of rock, 85 g
to 100g stemmed PMMA-LOXEx can breakoff approximately
1 t of rocks.

Fig. 3:
Image sequence of pit blasting from
the high-speed video documentation

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY
Fig. 4:
View of the excavated pit

Explosion cladding and impacting


With regard to the above, one test each was conducted
in 2011 and 2012. Test 1: Explosion cladding of Cu on steel,
according to the experiences of relevant industries.
Test 2: The component part that was to be blasted open
was applied on the carrier with meteoritic force.

Plating
Blasting open a 3mm thick, 30 cm wide and 40 cm long
Cu-plate on a construction steel plate of the same size. The
image segments of the image show the test procedure.
Above left: Sample preparation; right; blasting with a
total of 4.5 kg LOX-Ex. Below is the team with the welded
plate and on the right the sawed out sample stripes.
The detonation speed of PMMA-LOX-Ex was set at
approx. 4000 m/s up to 4500 m/s.

Issue 01 | 2013

Picture 6 shows on the left a close-up view over the area


of inter-metallic alliance between steel and copper (the
beam shows the measure 50 m). The right section of the
picture shows a typical wave structure with amplitudes of
up to 240 m, along the intermetallic contacting (Source:
DMC Dynaplat GmbH). Interestingly there was no wave
formation with LOX-EX-Plating.
Fig. 5:
Explosive plating of Cu on construction steel

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TRANSFER OF TECHNOLOGY

Fig. 6:
Left - close-up view of the LOX-EX-connection, right- typically occurring wave structure over the connection (DMC Dynaplat Co)

Impacting
Contrary to plating, where metal parts are rolled into
each other through blasting, the goal of impacting is to
explosively connect small-area and conventionally unweldable metals through direct exposing and higher
speed. During the tests a Cu-, as well as an AI plate with
thicknesses of 3 mm and 50 mm square were flatly exposed
on a construction steel plate with measures of 20 mm
thickness and 100 mm square, through 300g LOX-EX.
Picture 7 shows the impacted plates immediately after
the test. In the upper part of picture 8 micro-sections over
the inter-metallic interface of AI and in the lower part the
one of the CU steel bonding is shown.

Fig. 7:
Left- Impacting CU on steel and
right AI on steel

Issue 01 | 2013

Based on the chosen experiment setting and the data


of explosives, the estimation method according to De
Carli and Meyers for speed of flyr plate (3) resulted in
impact velocities of approx. 2600 m/s for the CU plate and
4400 m/s for the AI plate. Under the same conditions, in
case of usage of C4 in place of PMMA-LOX-Ex, the Cu
plate would have impacted the steel with 2200 m/s and the
aluminium plate with 3400 m/s.

Serial shots of LOX-Ex capsules on


gypsum and greywacke rocks
In 2011 and 2012, further technical developments were
done and extended tests were conducted on the drilling
and blasting method, also called LOX-Ex-Method (2).
Hereby special, simply constructed PET capsules were
filled with LOX-Ex and shot on gypsum- and greywacke
rocks, as well as on a quarry rock face.

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TRANSFER OF TECHNOLOGY
Fig. 8:
Above: microscopic view of the
metal connection AI and below
CU on steel

Picture 9 shows the set up of


the pneumatic shooting site, which
consists of the remotely controlled
loading preparation and the shooting
device (transvector).
Left in picture 10 some PET capsules
are shown before the pre-cooling
and filling, and right in the picture a
snapshot of the baring in successive
penetration into the rock is shown.

Fig. 9:
Ready for operation plant, according to the
LOX-Ex method

The graphics in picture 11 show


development of the vertically tapped
depth- or penetration profile, for two
shots (above) and the absolute depth
development, in connection with the
number of shots (below). The graphics
pertain to the tests shown in pictures 9
and 10, where the same location in the
quarry wall was permanently shot at.
One PET capsule is filled with approx.
75 g PMMA-LOX-Ex. A free greywacke
rectangle of a size of approximately 1.2 m3
was also shot at. This rock is considerably
harder than gypsum and anhydride rock.

Fig. 10:
Left- PET capsules and right- rock baring/penetration into the rock face

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY
Depth Profile Vertical

Fig. 11a:
Depth Development of the
Penetration Process

After the first four hits the rock already


showed a three-dimensional tear system,
which permeated approximately 2/3 of
the rock volume. Picture 12 shows the
greywacke rocks. After three more shots
bigger rock segments started to break out.
These tests with the LOX-EX-method
already show that with PMMA-LOX-EX the
excavation performance is twice as much
as with the method that is run with C4 and
which was developed in the 1970ies by Loui
and the AAI Corporation (4).

After 10
shots
After 5
shots

First test according to the


Imloch blasting method
The Imloch- drillblast method (named
according to the Imlochhammer- drill
method) is a special application form of the
LOX-EX-method. The difference is, that a
sack borehole is installed in the rock with a
drilling machine, in which a LOX-Ex load is
shot. See scheme of picture 13.
In the first test of the method, the loop
drilling- shooting in was passed through
three times. The drillings were done with a
hand drill and were therefore not ideal with
regard to their diameter quality and depth
(manually only 10 to 15 cm per drilling could
be achieved)

Drilling depth development

drilling depth [m]

Three shots were fired. Each shot broke


off rocks in a funnel-shape around the
drilling. Picture 13 illustrates the method.

Fig. 11b:
Depth Development of the
Penetration Process

Issue 01 | 2013

number of shots

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TRANSFER OF TECHNOLOGY
Fig. 12:
State of greywacke rock, approx.
1.2 m3, after the 7th shot

In case drillings are set accurately and by


machine, specific rock break-offs of more than
400 kg per 100 g of LOX-Ex can be expected,
independent of the rock type. This method can also
be applied in an automatized way and possibly
in combination with adits and tunnel boring
machines.
This is particularly possible in case mechanical
and rock-breaking tools fail in particular rock
formations. An advantage is, that with PMMALOX-Ex , no poisonous gases are generated and
the dust can be removed by normal ventilation.

Fig. 13:
Principle of Imloch drillblast
method

Initial Developments and tests of


LOX-EX-fuses
Lox-EX explosive can be ignited safely and reliably with
commercial electrical detonators.
Why use LOX-EX fuses?

In case small portions of LOX-EX loads are brought to


reaction in an automated way, a classical electrical
detonator would boost costs per ignition of load.

Tests have shown (WIWEB 2008) that in case of igniting


LOX-EX-loads with EL detonators, the detonation speed
increases to the final speed after a distance of 2 to 3 cm.
This distance is too much if geometrically small loads are
used.

Fig. 14:
Test of the Imloch Drillblast method

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY

Electrical cables are inexpedient during firing of


capsules

During impact- welding tests it has proven beneficial, if


the detonation speed is accelerated from almost zero to
full speed, in order to keep the amount of explosives low.

LOX-Ex- fuses only become explosive in contact with


liquid oxygen.

The fuses or detonation accelerators used up to


now have been selected from the field of corruscatedexplosives (5), i.e non-gas producing explosives.
This type of LOX-Ex fuses are currently applied to

The LOX-Ex-Method

The booster-ignition of impacting and compacting tests


and

The pneumatic, remotely controlled ignition of LOX-Ex


loads.

Picture 15 shows two examples of utilization of such


fuses. On the left a naked heat shell capsule for the
LOX-Ex method can be seen. A hard gelatine capsule is
under the tip of the liner, which contains an appropriate
coruscate. In the moment of collision the coruscate in
the LOX-Ex ignites and immediately causes acceleration
of detonation speed to the maximum value. This happens
even before the proper motion of the capsule in collision
damages the geometry. In the right part of the picture there
is a tiny booster load at the tip of the electro- detonator
(black arrow). This load is activated through the fuse and
acts as detonation accelerator, so that a successful
impact-welding of small objects becomes possible with
relatively small LOX-Ex loads.
Fig. 15:
Coruscated, LOX-based ignition
and detonation accelerator

Issue 01 | 2013

Bibliography
[1] C. Becker: Ein Kryosprengstoff der neuen Generation; 17.
Kolloquium Bohr-und Sprengtechnik, TU Clausthal, Januar 2011.
[2] B. Schwark-Werwach: Ein neues Verfahren zum
automatisierten Sprengvortrieb; 17. Kolloquium Bohr- und
Sprengtechnik, TU Clausthal, Januar 2011.
[3] P. S. De Carli and M. A. Meyers: Design of Uniaxial Strain
Shock Recovery Experiments; Preprint from: Shock waves
and high-strain-rate phenomena in metals (1981); Poulter
Laboratory, SRI-International Menlo Park , California 94025
U.S.A.
[4] Maurer, W. C.: Advanced Drilling Techniques, ISBN 0-87814117-0, Petroleum Publishing Co., Tulsa, Oklahoma 74101, 1980.
[5] C. Becker: Neue Methoden zur Sprengung
Umweltschonend und Kostengnstig; Public Security
Energie & Rohstoffe 1-2012.
[6] Videodokumentationen und Verffentlichungen zu den
LOX-Ex-Versuchen des INBT im Internet; s. youtube, Kanal von
Aruncillos .

Dr. rer. nat. C. Becker


Institute for New Basic-Technologies
(INBT)
Alte Leipziger Str. 50
99734 Nordhausen

Dr.-Ing. B. Schwark-Werwach
Institute for New Basic-Technologies
(INBT)
Alte Leipziger Str. 50
99734 Nordhausen

FOR MORE INFORMATION AND CONTACT:


| c.becker@inbt.de |
| b.schwark-werwach@inbt.de |

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TRANSFER OF TECHNOLOGY
Literaturverzeichnis
Dr. rer. nat. C. Becker

[1] C. Becker: Ein Kryosprengstoff der neuen Generation; 17.


Kolloquium Bohr-und Sprengtechnik, TU Clausthal, Januar 2011.

Institut fr Neue Basis-Technologien


(INBT)

[2] B. Schwark-Werwach: Ein neues Verfahren zum


automatisierten Sprengvortrieb; 17. Kolloquium Bohr- und
Sprengtechnik, TU Clausthal, Januar 2011.

Alte Leipziger Str. 50


99734 Nordhausen

[3] P. S. De Carli and M. A. Meyers: Design of Uniaxial Strain


Shock Recovery Experiments; Preprint from: Shock waves
and high-strain-rate phenomena in metals (1981); Poulter
Laboratory, SRI-International Menlo Park , California 94025
U.S.A.

Dr.-Ing. B. Schwark-Werwach
Institut fr Neue Basis-Technologien
(INBT)

[4] Maurer, W. C.: Advanced Drilling Techniques, ISBN 0-87814117-0, Petroleum Publishing Co., Tulsa, Oklahoma 74101, 1980.

Alte Leipziger Str. 50

[5] C. Becker: Neue Methoden zur Sprengung


Umweltschonend und Kostengnstig; Public Security
Energie & Rohstoffe 1-2012.

99734 Nordhausen

[6] Videodokumentationen und Verffentlichungen zu den


LOX-Ex-Versuchen des INBT im Internet; s. youtube, Kanal von
Aruncillos .

WEITERE INFORMATIONEN UND KONTAKT:


| c.becker@inbt.de |
| b.schwark-werwach@inbt.de |

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Tough going for man and machine


by Tilo Jautze | Veit Passmann | Mario Schniger
Thyssen Schachtbau GmbH | Germany

Fig. 1:
Raise boring HG250 while drilling

n July 2008 RAG issued a call for tenders for the sinking of a new staple shaft at West colliery.
The bidding consortium ventilation borehole F275 comprising partners Thyssen Schachtbau
GmbH and DHSS GmbH has tendered successfully for RAG vertical development projects for
a number of years and the client also entrusted this challenging engineering project to the
experience and know-how of the F275 consortium.

Technical background
Ventilation borehole F275 was constructed by raise
boring to a diameter of 3.66 m and a depth of 320 m. Its
completion meant a new ventilation route to the two
proposed new working panels 630 and 632 in the deeplying Girondelle seam.
Given the existing shaft parameters it was decided to use
a Wirth type HG 250 raise boring machine for sinking the
staple shaft. In order to achieve the directional accuracy
specified by the client a Micron self-adjusting rotary vertical
drilling system (RVDS) was employed in conjunction with a
10 drill string for the 12 directional borehole. After
the pilot hole had been drilled to completion the directional
drilling system with its roller bits was replaced by a Sandvik
3.66 m-wide raise boring head fitted with 20 monobloc disc
cutters.

Issue 01 | 2013

Raise boring:
Raise boring is a technique for drilling largediameter boreholes in solid rock. Raising means using
a dry drilling process whereby an extension drilling
head fitted with discs gradually cuts its way to the
surface.
The largest raise boring machines currently in
operation can draw up to 1,500 tonnes. This class of
machine can drill shafts more than 6.0 m in diameter
and up to 1,000 m in depth depending on the strength
of the local rock strata. One of the prerequisites of the
raise boring method is to have access at the bottom end
of the hole in order to clear away the debris produced
as the machine cuts its way upwards.

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TRANSFER OF TECHNOLOGY
Pilot drilling
The assembly and equipping work began at West
colliery in November 2008, though the pilot drilling did not
commence until 21.01.2009 due to a delay in completing
drivage E550 for the bottom roadway.
This lower road was to be widened to create a chamber
that would constitute the end-point for the staple shaft
with its shaft bottom. The pilot hole had to break through as
accurately as possible to the centre point of this chamber.
In order to achieve this level of directional accuracy it
was decided to use a self-adjusting vertical drilling system,
which is capable of a drilling precision of up to 0.3%
deviation from the vertical. The pilot hole was drilled using
a rotary, direct flush boring technique (direct circulation
method) and the drill mud in this case clean water was
fed to the drilling unit by means of a twin piston pump.
The drilling operation started off smoothly and after
seven days the pilot hole broke through to the chamber.
The deviation from vertical was about 15 cm. The RVDS did
not have to be changed over and completed the entire 320
m without a hitch.

The entire drill string was then removed and the RVDS
with its drill bits dismantled. The drill string was then
reassembled and connected to the raise boring head so
that the raise boring machine with its connecting rod could
be set up in the shaft bottom chamber. Once this assembly
work had been completed the chamber was sealed off
with a baffle wall, for safety reasons, so that the drilling
debris falling down the raise hole would not pose a risk to
men and machinery. A small opening was left in the right
side of this screen to provide access for a chain conveyor
that would gather up the material as it came piling over the
top of the debris heap and transport it directly to the main
belt installation.

Hole widening
All the preparatory work was completed by 11.02.2009
and the raise boring phase could begin. Unfortunately
the drilling team realised after just a few metres that the
geological conditions were far from ideal for a raise boring
operation. During the first 30 m there were major rock
collapses that prevented the drilling head from cutting
uniformly and steadily. Add to this the fact that these large
blocks of rock, some of which measured up to 0.5 m in
size, occasionally caused damage to the drill head, which
then had to be repaired.

Fig. 2:
Assembling of the reaming head
at the bottom of the blind shaft

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY
After discussions with Sandvik it was decided that
the raise boring head should have its cutter arms and
disc cutters strengthened so that the normal drilling
performance could be achieved even under such difficult
conditions. Some of the drilling parameters, including
contact pressure and rotational speed, were also adjusted
to meet the challenge. As soon as these measures had been
implemented the boring operation was able to continue at
a quite acceptable rate of advance.
The extremely large-sized debris also posed loading
problems at the foot of the shaft: the larger blocks
sometimes jammed the chain conveyor and transfer point
to the belt installation and had to be reduced in size. This
meant frequent belt stoppages, which had a major impact
on the drilling work and resulted in significant delays.
The enormous mechanical stress imposed on the drill
head, combined with the frequent changes in the geological
make-up of the strata harder rock alternating with soft
to very soft ground also meant that the drill head had
to be repeatedly inspected and cleaned. The entire hole
widening operation lasted until 04.06.2009.
Despite the delays imposed by the poor geomechanical
conditions the operation was completed within the planned
time frame thanks to the introduction of week-end working
shifts.

Shaft support
After the drilling operation had been completed on
schedule the shaft support phase was able to commence
as planned in June 2009. RAG also commissioned the F275
consortium to carry out this part of the overall project.
The infrastructure required to complete the support
work was set up around the top of the shaft opening. This
comprised a rope pulley frame, a platform winch, two
hoisting winches for men and materials, an emergency
travel winch and a cablewire winch.
The ventilation shaft was to be lined with a layer of
shotcrete at least 5 cm thick to support the inner face of
the shaft column and, additionally, to act as a levelling
layer in those areas where breakouts had occurred. The
frequent side-wall collapses encountered during the raise
boring operations resulted in a much higher consumption
of shotcrete than originally planned and formwork had to
be installed in some sections before applying shotcrete to
level off the larger cavities that had formed in the sides
of the shaft. The shotcrete was delivered pneumatically

Issue 01 | 2013

Fig. 3:
Working stage and rope pulley

via a drop pipe and a Schuerenberg concrete pump was


used to dry spray the material into place. The material was
supplied by the client in big bags.
The shotcrete phase was followed-up by the installation
of a three-piece yielding ring support system combined
with a roll-mesh lining that was fixed directly to the
shaft wall. The very cramped working conditions for the
fitting and assembly team (shaft diameter 3.6 m) called
for an extremely precise operating routine and perfectly
coordinated logistics.

Pipework
As soon as the shaft lining had been completed the
operation then switched to the installation of some 15 inshaft pipe columns. This comprised two fully-supported
GRP pipes plus a total of 13 tension-proof socket
connections with their mounting points at the top of the
shaft. Screw couplings were also used for various pipes
that would supply the new working panels with water, gas,
air and calcium chloride (CaCl2).

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TRANSFER OF TECHNOLOGY
The final phase
The final piece of equipment to be installed was a small
cage system that would be used for regular descents of
the shaft in order, for example, to examine the condition of
the pipes. This installation comprised a rope pulley frame,
winch and travel cage. The cage itself ran on a tensionrope guidance system, with boarding and alighting points
provided at the top and bottom of the shaft.

Conclusions
Despite all the problems and unforeseen obstacles
staple shaft F275 was finally delivered on time, and fully
equipped, in March 2010. The completion of F275 signalled
the go-ahead for the first panel in the Girondelle seam to
be started up.

Authors:

Tilo Jautze

Veit Passmann

Mario Schniger

Source: Thyssen Schachtbau Mining Report 2012/2013


THYSSEN SCHACHTBAU GMBH
Sandstrae 107 - 135
45473 Mhlheim an der Ruhr
www.thyssen-schachtbau.de
Tel.: +49(0) - 208 - 3002 - 0
Fax: +49(0) - 208 - 3002 - 327
eMail: info@ts-gruppe.com

Fig.:
Raise boring HG250 while drilling

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY

Analysis of transfer stations of belt conveyors


with help of Discrete Element Method (DEM) in
the mining industry

by Dr.-Ing. Andrey Minkin


ContiTech Conveyor Belt Group |
Mining Europe |Northeim | Germany

ntroduction: Steady growing demand on row materials in emergency markets boosts a


development and improvement of bulk material equipment in mining industry. Belt conveyors
and their elements remain most popular mining equipment due to its very high productivity.
Transfer stations are widely used for belt conveyors, where a bulk material is transported
over long distances and/or complex mine or nature terrains. In the mining industry heavy and
hard bulk materials (e.g. crushed rock or similar) must be transported very often. In this case
a carefully designed transfer station essentially contributes for a long life time of a conveyor
belt. The behavior of a bulk material flow in a transfer station is very complex and cannot be
described sufficiently by an analytical model. The analysis of alternative designs of a transfer
station can be aided by using a numerical simulation based on the Discrete Element Method
(DEM) before a transfer station is ever built.
DEM was developed in the 70th of the
twenty century by Cundall for geo- and
rock mechanics and is widely used now for
simulation of material handling equipment [1].
From many numerical methods the DEM-method
is the most representative one to describe a
complex dynamic behavior of the discrete and
discontinuous processes, which is e.g. the
transportation of bulk materials.

Table 1:
Typical transfer station designs used in the mining industry

Impact wall

Rock box

Transfer stations and feeding points remain


one of the most important and challenging
units of belt conveyor systems, because a poor
designed transfer station may cause:

Build-ups and plugs in transfer stations


resulting in high downtime of production

Dust, noise and spillages around the conveyor


system

Essential wear or destruction of a conveyor


belt, transfer station elements and idlers

Belt misalignment due to not a central loading

Source: RWE, Germany

Hood - spoon system

Grizzly fingers

Following transfer station types are widely


used in the mining industry: Impact Wall, Rock
Box, Hood-Spoon-system and Grizzly Fingers
(Table 1).

Source:
Gulf Conveyor Systems Pty Ldt., Australia
Issue 01 | 2013

Source:
Jadco Manufacturing Inc., USA
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TRANSFER OF TECHNOLOGY

Fig. 1:
3D simulation models of the transfer chute geometry

All types of the above mentioned transfer chutes have


advantages and disadvantages and should be applied
depending on bulk material properties, conveying
parameters, site conditions etc. This article focuses on
the Rock Box type.

Design consideration for two rock boxes


One existing and one alternative transfer stations with
a different geometry and position of the rock box were
considered in the two simulations. The simulation models
were generated on the base of the CAD drawings offered
by one mining company. They are shown by Fig. 1. The
models are named after the Existing Rock Box (ERB) and
the Alternative Rock Box (ARB).
The bulk material rock was simulated with the following
particle size distribution:

Approx. 40% of total mass: 110 mm < dK < 150 mm

Approx. 60% of total mass: 37 mm < dK < 74 mm

The simulation parameters were chosen after the


analysis of the given rock sample. The following operational
parameters were considered in the simulation models.

Results of DEM simulation


Figure 2 shows the steady state situation of the material
flow of the two transfer stations. Due to the narrower wide
of the chute in the configuration ARB, the material builds
up higher on the receiving belt. Regarding also the lower
position of the rock box in this configuration hardly any
accelerating distance for the down falling of particles can
be recognised.
The material which flows down the rock box is generally
directed against the conveying direction of the receiving
belt. Fig. 3 shows this even clearer via the vectors of the
particle velocity.
The steady state condition can be not only recognised
by the observation of the material flow but also by the
analysis of the acting forces on the rock box. Fig. 4 shows
the forces due to the particle impact on the rock box in
transport direction (x-direction). After a certain time nearly
constant values of both forces are measured.
Although the particles hit the ARB- rock box with a
higher velocity, lower impact forces in x- direction could
be measured. This is caused by the higher particle velocity
component in z-direction due to the increased distance
from the drum.

Table 2:
Operational parameter of the simulation models

Case Drawing Volumetic


flow

Issue 01 | 2013

Belt
velocity

Belt
Troughing
Angle

Material Trasnition
Surcharge Distance
Angle

Material
Density

ERB

20.000 t/h

7,6 m/s

35

12

3,8 m

1,9 t/m

ARB

20.000 t/h

7,6 m/s

35

12

3,8 m

1,9 t/m

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TRANSFER OF TECHNOLOGY

Fig. 2:
Simulated material flow. Particle colour: Particle velocity: 0

The forces on the rock box acting in gravity direction


(z-direction) are mainly influenced by the weight of the
stored bulk solid on the rock box. Fig. 5 shows that the
ARB rock box is loaded with a smaller force in gravity
direction. A measurement of the stored bulk solid mass in
steady state condition results in a weight difference of 1030
kg between the two rock box designs. The reason for this
is the much more narrow design of the ARB rock box.

>10m/s

But not only the forces on the rock box could be


measured. Also the impact forces on the receiving belt
were measured in the simulation. This allows a prediction of
belt wear. Fig. 6 shows the measured belt impact forces of
the both transfer stations. The transfer chute configuration
ARB shows clearly less impact forces due to the lower
distance of the rock box to the belt.

Fig. 3:
Particle velocity vectors and impact direction on the receiving belt

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY

Fig. 4:
Forces on the rock box caused by the particle impact (x-direction)

Fig. 5:
Forces on the rock box caused by the mass of stored material (z-direction)

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY

Fig. 6:
Impact forces on the receiving belt

Conclusions
The DEM simulation of two rock boxes showed that by
means of the DEM superior design could be identified and
the higher wear impact on a belt reduced at the design stage
with less cost. Summarizing it can be mentioned, that DEM
is a powerful tool, which can be used for the development,
design and calculation of conveyors and their elements
and for problem solving in conveyor technology.

Dr.-Ing. Andrey Minkin


ContiTech Conveyor Belt Group
Mining Europe
Northeim, Germany

References
[1] Itasca Consulting Group Inc.: PFC3D Theory and
Background.
[2] GRGER, T., KATTERFELD, A.: Application of the
Discrete Element Method in Materials Handling: Basics
and Calibration; Bulk Solid Handling, Vol. 27 (2007) Nr. 1

Contact:
Dipl.-Ing. Andrey Minkin
ContiTech Conveyor Belt Group
Breslauer Strae 14
D-37154 Northeim
Tel. +49 (0) 5551-702-207
Fax +49 (0) 5551-702-504

[3] KATTERFELD, A., GRGER, T., MINKIN, A.: Discrete


Element Simulation of Transfer Stations and their
Verification: Bulk Solids & Powder Science & Technology,
Vol. 2 (2007)
[4] MINKIN, A., KATTERFELD, A., GRGER, T.: The Usage
of the Discrete Element Method in Conveyor Technology:
Screw Conveyors and Shaftless Screw Conveyors; Bulk
Solid Handling, Vol. 27 (2007) Nr. 2

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY

ContiTech Conveyor Belt Group | Phone +49 5551 702-207


transportbandsysteme@cbg.contitech.de

Please have a look at our social media service:

ADVERTISEMENT
Issue 01 | 2013

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42

TRANSFER OF TECHNOLOGY

Innovative Filler Removal to


Improve Quality of Crushed Sand

by Dr.mont. H.J. Gschaider


Binder+Co AG | Gleisdorf | Austria

inder+Co is an internationally successful specialist for machines and overall systems for
crushing, screening, drying and sorting, as well as for packing and palletizing of any kind
of bulk solids. The company, which is located in the Styrian Gleisdorf, is seen as the global
market leader in screen technology and glass recycling. Its machines are used for processing of
bulk solids, such as construction commodities, coal, ores, minerals, waste glass, waste paper,
plastics waste, chemical and petrochemical industry products, chemical fertilizers, salt, food and
animal feed. Within the field of processing of construction commodities, Binder+Co particularly
focuses on screening machines for special requirements. Responding to the growing demands
regarding overall cost-effectiveness of a processing plant, Binder+Co focuses on development,
implementation and integration of innovative screening systems.
Apart from ensuring the required product quality and
throughput rates, an important factor is minimizing the
costs of investment and operation, leading to a sustainable
success in mineral processing. Particularly in plant
alterations, the space available plays a major role and
calls for tailored solutions with regard to process and
mechanical engineering. With the overall goal of offering
optimum solutions, Binder+Co promotes continuous
advancement and new product development.

Issue 01 | 2013

Fine screen mats for BIVITEC- screening


machines
For many years, the special screening machine BIVITEC
has been successfully operated to produce high quality
crushing granulation. Several screen mats are applied for
crushed sand screening or crushed sand filler removal.
Punching mats with mat thicknesses of 2 to 7 mm are used
to produce the classical separating cuts 8mm, 5mm and
2 mm, with square or slotted perforations, based on the
task.

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TRANSFER OF TECHNOLOGY
lead frame

0,2 mm line-perforation

precision frame

80 m quadratic perforation
The so-called filler removal requires corresponding
fine perforations. In the past, mostly longhole perforation
mats with mat thicknesses of approximately 1 to 2 mm
have been used. The corresponding width of the hole lies
in areas between 0.8 and 0.2mm. Holes of sizes 0,5 mm x
5 mm, 0,3 mm x 3 mm and 0,2 mm x 4 mm are often
used.
A relatively new development of Binder+Co is the BIVITEC
precision tissue mat. Here, fine tissue cuts are inserted into
a form of synthetic-basic frame. The respective fine tissue
is characterized by exactly defined and systematically
controlled, reproducible tissue characteristics, such
as mesh size, thickness, tear resistance and dimension
stability. The standard mesh sizes used for crushed sand
filler removal are 315 m, 210 m, 177 m and 105 m. The
finest BIVITEC precision tissue mat currently has a mesh
size of 80 m.

Approach to technical screening


machine construction
In order to optimally design the screening machine,
usually filler removal separating cut screening tests
are conducted with a pilot plant screening machine. As a
first step, the feeding rate is determined with the help of a
computer programme that is programmed on the basis of
a factor method. The testing machine has an effectively
usable screening length of maximum 2.33 m and is adjustable

Issue 01 | 2013

Fig. 1:
Perforation mat and precision tissue mat

in its inclination. In most cases a simple screening attempt


through one time feeding of the screenings and sampling
of the two production streams would not or would only
approximately correspond to a large-scale screening. In
order to optimally design the required screening surface
area, the following path is taken: The required feeding
amount of approximately 1 m bulk goods for each test
series is fed into the screening feed hopper, located in the
technical center of Binder+Co in Gleisdorf. The first part
of the test is started, considering the calculated screening
duration, and after reaching a continuous operation state,
representative sampling from both screening products
and charging material is started. Hereby the entire stream
of material is temporarily captured with a sampling
container.
The collective samples obtained in this way are reduced
by riffle splitters or rotary dividers for the consecutive
sample analysis. The two product chutes lead the major
amount of the screening products into the coarse- and fine
material container. Similarly, the second phase of the test
is conducted with the coarse material produced in the first
phase of the test. Hereby the screening plant is operated
with a reduced feeding rate, so that the duration of both
sections is fairly equal. Based on the size of the task, it
might be necessary to conduct a third or fourth test phase
with the same duration. It is possible to simulate screen
lengths in the area of 2.33 m to 9.33 m.

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TRANSFER OF TECHNOLOGY
Aufgabe
A1.1

....representative
Reprsentative
Probenahme
....
sampling
tv1.1 = tv1.2 = tv1.3
Fig. 2:
Flow chart of the test procedure with three test phases:
Ai.j. Task, G i.j. coarse material, F i.j. fine material, tv i.j.
duration of the test phase, i. number of test series, j number
of test phase

tv1.1
G1.1 (=A1.2)
1
tv1.2
G1.2 (=A1.3)
2
F1.1

tv1.3
3

G1.3

F1.2
F1.3

For clarification purposes it should be noted that the


three screening machines numbered 1, 2 and 3, shown
in figure 2 refer to the same screening machine, but to
different test phases. This type of test not only ensures the
simulation of needed large-scale screen lengths or dwell
times, but also provides extensive data material (after
analysis of subsamples) for an optimal screening machine
dimensioning.

Case study
Over the last years, more than 20 new BIVITEC screening
machines were installed for crushed sand filler removal.
Currently single-, double, triple and quadruple deck
screening machines are in operation. In addition to the
filler removal, the double-decker machines allow for the
coarser separating cut of 2 mm with the upper deck, for
example. The separating cuts of the two-and- half decker
are 2 mm and 5 mm through the upper deck. The short
tween deck offers an additional screening area for the
separating cut 2 mm, and the lower deck is entirely used
for filler removal. The three-decker is in application for
three separating cuts, the four-decker for four separating
cuts.

Issue 01 | 2013

The screening of crushed granite is briefly outlined as a


case study. Approximately 65 t/h of pre-screened granite
of a nominal grain size 0/3 mm are to be feed into a threedecker BIVITEC screening machine. Each screening deck
has an effective width of 2.4 m and an effective length of 7
m, measured from the first to the last screen mat. In case
of only one impulse, the entire nominal screening surface
amounts to 50.4 m. The swing characteristic can be set
separately for each screen deck, or changed retroactively,
if needed. In order to achieve the separating cut 1 mm,
perforating mats are inserted into the upper deck. On
one hand the perforating mats of the tween deck protect
the precision fabric of the lower deck, on the other hand
they allow for an additional separating cut of nominally
0.3 mm. This is followed by four screening products.
The two overflows of the tween and lower deck can be
combined partly or totally, as required (see fig. 3 a). On one
hand this allows to react to changes in the fed material,
on the other hand it gives the opprotunity to produce end
products with various grain compositions or various filler
contents. Figure 3 b shows a special screening machine in
the production hall at Binder+Co in Gleisdorf. The machine
was delivered at the end of 2012 to South Germany and will
be integrated into a plant to process crushed sand.

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TRANSFER OF TECHNOLOGY
feeding 0/3 mm

filler 0/63 m

e.g. filler removal


of Crushed Sand
Fig. 3a:
Schematic Diagram three-decker- BIVITEC

Fig. 3b:
Three-decker BIVITEC for granite screening with precision fabric mats in the under-deck

New development Air-supported fine


classification
In its newest innovation, Binder+Co mineral engineering
combines screen and air technique and offers major
advantages for the filler removal of crushed sands:

Space saving

More possibilities to change separation characteristics

Lower fine sand losses

Better end product qualities

This new development can be divided into


two areas that are connected in series. As
a core component, the first area contains
dynamically charged separators that, similar
to a screen mat of a BIVITEC screening
machine, are constantly stretched and
compressed. The crushed sand, which is to
be filler removed, is conveyed downwards
over the inclined separation plane, at the
end of which the coarse material (filler
removed crushed sand) flows over. There is
no resonating dust removal pipe in screening
machines at the machine covering. Instead,
various air inlets can be inserted in the cover
area. There is a new gas cyclone, either
Fig. 4:
Schematic diagram of the new development

Issue 01 | 2013

under the perforated separating elements, or inserted


downstream. Fig 4 shows the sketch of a possible model
of this development with horizontal cyclone.
The fine material (filler product) is actually sucked
through the separating elements with an exhaust device
and then separated with the help of the gas cyclone.
The particular shape of this cyclone is different from
conventional cyclones in the sense that the crude gas
inlet in the cyclone is slimmer and ranges over the entire
cylindrical height, it has a continuous drawbar in the
cyclone axis and the conic casing is shaped considerably
shorter (see figure 5).

parting element

coarse material

ventilation

fine material

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TRANSFER OF TECHNOLOGY
Fig. 5:
3D- sectional model of the new gas
cyclone with continuous drawbar

entry of crude gas

conduct

The separator system is characterized


by a smaller screening area, by mats with
small openings (e.g. 0.2 mm x 4 mm), as well
as by high dynamics. This prevents clogging
of the perforations despite the high air flow
(or the respective under-pressure in the area
of separating elements) and supports the
detaching of adhering grains and dissolving
of agglomerates during the transport of
the coarse material over the separating
elements.

concentration of removal filler in coarse material

coning
cover

inverse value of specific rate of feeding [m/(t/h)]


measurement without ventilation

measurement with ventilation

compensation

compensation
Fig. 6:
A comparison of test results

Issue 01 | 2013

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TRANSFER OF TECHNOLOGY
Initial comparative filler removal tests in the technical
center of Binder+Co were conducted in late 2012. Crushed
sand with a nominal grain size of 0/2 mm from a German
limestone processing plant with a filler content of 22%
served as feedstock. The filler content is defined as the
mass fraction of the grain size category <63 m in the sand
product. During the analysis of the test data, a specific
feed rate was defined, as the relation of feeding rate (t/h)
to the available nominal screening surface (m2).
In figure 6 the reciprocal value of this specific feeding
rate is recorded on the x-coordinate. This reciprocal value
specifies the amount of square meters of screening area
per 1 t/h crushed sand feeding, which has been provided
for the filler removal. The filler contents < 63 m of the
coarse material are recorded in percentage on the y-axis.
The filler contents of the feeding material are assigned
to the x-axis value zero. The more of screening area or
separating area is made available per t/h feeding material,
the lower is the corresponding filler content in the coarse
material.
Blue rhomb symbols were used to present the results
of the classical screening filler removal tests, and a blue
compensating curve was drawn to characterize the
screening behaviour. Similarly, the red squares and the red
curve show the air-supported classification with suction
and gas cyclone. The initial summarizing statement is:
Compared to the classic screening filler removal, the airsupport only requires half of the separating area for the
same amount of filler content in the coarse material.

Bibliography

Author:
Dr.mont. H.J. Gschaider | Binder+Co AG

Dipl.-Ing.
Dr.mont.
Helfried
Gschaider studied mining and
processing at the Montan-University
Leoben in Austria. Between 19911997 he first was an assistant for
processing of industrial projects
and then an assistant Professor at
the Department of Processing at
this university. Sinve november 1997
he is working for the Binder + Co AG in the areas of process
engineering, project management and sales with a focus on
screening, wet processing and sensor based sorting.
| office@binder-co.at | www.binder-co.com |

Contact:
Dr.mont. H.J. Gschaider
Binder+Co AG
Grazer Strae 19-25
8200 Gleisdorf, Austria
Tel.: +43 (0)3112 800-0
Fax: +43 (0)3112 800-300
eMail: office@binder-co.at
Internet: www.binder-co.com

Please visit us at Bauma 2013


Hall B2 | Booth 205

[1] Gschaider, H.J. und Kalcher, A.: Qualittssteigerung von


Brechsanden durch siebtechnische Abscheidung von
Feinststoffen/Improving the Quality of Crushed Sands by
Screening Off Very Fine Materials, Aufbereitungs Technik/
Mineral Processing, 42 (2001), Nr. 7, S. 328/335.
[2] Brunnmair, E., Dunst, F. und Flachberger, H.: Neuartiger
Gaszyklon mit differenzierter Grob- und Feinabtrennzone,
BHM, 154. Jg. (2009), Heft 12, S. 610/613.
[3] Eixelberger, R.: Unverffentlichte Versuchsauswertungen,
Binder+Co, 2012.

Issue 01 | 2013

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48

TRANSFER OF TECHNOLOGY

Mining specialist
BBM Maschinenfabrik Meran presents
roadheader at BAUMA 2013

Fig. 1:
The BRH 130 is designed for high performance and low
wear. The illustration shows the design for a salt mine
(photograph: BBM)

he highly efficient BBM Group, based in the city of Mlheim an der Ruhr, has for decades been
one of the leading and deeply rooted service partners of the German coal mining industry.
BBM has also acquired an excellent reputation internationally. For nearly two years BBM has
also been on the market with the firm BBM Maschinenfabrik Meran GmbH as a manufacturer of
high-performance mining machines and supplies a wide range of technical equipment such as
roadheaders, roof cutters and milling loaders. With the BRH 130, BBM Meran are presenting at
BAUMA 2013 the revised version of a selective roadheader that has long proved its worth.
True to BBMs slogan Quality leads to Quantity, the
crawler-mounted BRH 130 equipped with a cross-cutting
head displays all of the features to make it an efficient,
safe and durable high-performance device when driving
roadways and galleries , as well as during mining operations
under the most adverse conditions.
With the 160 kW of power installed for driving the
cross-cutting head, it can cut minerals and rocks with a
compressive strength of up to 100 MPa. During the cutting
work, claws relieve the load on the crawler chassis and
increase the stability. Intrusion cutting is also performed
with the crawler chassis supported by the hydraulic, zeroplay 400 mm advance motion. This is a significant advantage
compared to the fixation via the crawler chassis which has
been standard practice so far.

Excellent equipment and optimum


ergonomics
The front shovel can be expanded in various ways.
The loading system with scraper blades, which feed the
excavated material to the central conveyor, is very robust.
The central conveyor is equipped with a central chain

Fig. 2:
The BRH 130 is versatile and can be used in various
fields of application, such as in coal mines using the
design shown in the illustration above (photograph:
BBM)

Issue 01 | 2013

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49

TRANSFER OF TECHNOLOGY
and scrapers and optionally available as a double-chain
conveyor. For the discharge a sufficiently large conveyor
cross-section is available. The machine can be operated
by radio remote control - with visualisation on a monitor
being provided in the rear of the machine - or by a control
unit with an electronic profile control system display and
the required operating and monitoring equipment, which
is arranged on the side of the machine. The operators
cab provides the machine operator with a good view
of the working face. The drivers seat and the elements
arranged around the drivers seat are designed according
to ergonomic principles and thereby help the driver to work
safely and without becoming tired.
For the hydraulic supply of all drives there is a double
pump unit installed.

High performance and low wear even


under extreme conditions
The cutting drive of the machine is equipped with a
cross-cutting head. 160 kW of electrical drive power for
the cross-cutting head. Rugged helical cutting gear for
extreme loads. Loading system with robust scraper blades
and cylinder drive. Another advantage of the BRH 130 is
the 400 mm displacement in the longitudinal direction of
the cutting arm and centre support with slide.
This allows the intrusion cutting to be performed from a
stationary position while the roadheader rests on claws.
Supporting the machine during cutting protects the chassis
and above all the floor.
All of this makes the BRH 130 an investment which is
worthwhile because of the high efficiency levels, service
life and low rate of wear.
For the adaptation of the BRH 130 to different application
requirements the following optional additional equipment
is available:

machine cover with integrated dust extraction channels

cooling system for high ambient temperatures

anchor drilling rig

swivelling belt conveyor

lining placement device

working platform on the cutting arm

radio remote control

cutting arm sprinkling air - water

loading table widening, variable

Issue 01 | 2013

Fig. 3:
Additional optional equipment from up to down: cutting
arm sprinkling air-water, profile control system, wireless
remote control (photos: BBM)

automatic lubrication system

profile control system

In addition, there is the possibility of equipping or


adapting the roadheader according to individual customer
wishes.

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TRANSFER OF TECHNOLOGY

Fig. 4:
Dimensions of the BRH 130 (photograph:BBM)

Tables 4 & 5:
Dimensions of the device and radii of action of the machine BRH 130

Dimensions of the device and radii of action of the


machine
Total weight
55 t
Overall length
11.600 mm
Overall height
2.000 mm
Height above conveyor
1.750 mm
Loading table width
3.700-4500 mm
Crawler width
600 mm
Conveyor speed
0,6 m/s
Diameter of the cutting roller
750 mm
Tank volume
600 L
Feed length from stationary pos.
400 mm
Lowering of the loading table
200 mm
Lifting of the loading table
200 mm

Cutting profile:
Cutting height
Cutting width
Undercut
Cutting speed

4.200
4.500
200
3,2

mm
mm
mm
m/s

Field of application of the machine:


Minimum width of the gallery
Minimum height of the gallery
Smallest curve radius

2.200 mm
2.500 mm
6.000 mm

Electrical system:
Standard operating voltage
Total installed power
Cutting head drive
Frequencies

Issue 01 | 2013

1000/50
290
160
50

V/Hz
kW
kW
Hz

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TRANSFER OF TECHNOLOGY
Fig. 5:
The big sister of the BRH 130, the
BRH 300/400 (photograph: BBM)

Please
visit us!
Hall C2, Booth 507

Contact:
Operta-BBM
Dieter-aus-dem-Siepen-Platz 1
D-45468 Mlheim an der Ruhr
Tel.: +49(0)208 459 59-0
Fax: +49(0)208 459 59-59
eMail: info@operta-bbm.de
Internet: www.operta-bbm.de

A wide range of mining machines


Besides the BRH 130, BBM Maschinenfabrik Meran
has other machinery for use in the mining industry in
its range. Like the BRH 130, these also feature high
levels of performance and stability and quality Made in
Germany.
BBM has been working in the field of mining for
decades. As a result the company is able to integrate its
practical experience under ground into the development
and manufacture of machines. The result is machines with
robust technology, highest safety levels and output on the
one hand and as little wear and tear on the other.
Roadheaders:
BRH 300/400 BRH 130 BRH 178/300
Milling loaders:
BML 50 BML H BML B 110 BML N 110
Roof cutters: BFT 110
Excavator cutting head: BRQ 110
Convince yourself of the performance of BBM
Maschinenfabrik Meran and their machines and services
at BAUMA 2013.

Issue 01 | 2013

BBM Maschinenfabrik Meran:


professionals for professionals also in
the fields of maintenance and repair
Each hour of downtime costs a lot of money and
reduces productivity. Especially where the conditions
are harsh, the regular professional maintenance of
machines is therefore particularly important. Because
this can be planned, whereas fault-related downtimes
cannot. At BBM Maschinenfabrik Meran customers
have an experienced and flexible service team at their
disposal. Not only when standard maintenance is due,
but also when repairs are required to ensure that the
machine can be quickly put back into use.
Another offer of BBM Meran is the repair and
modernisation of second-hand machines. Sometimes
this is a reasonable alternative to the purchase of new
machines from the economic perspective. Old machines
are restored to their original condition both technically
and with respect to their safety and can subsequently
be used again.
Also in this case BBM Meran provides its customers
with support, from the initial consultation, the inventory
or procurement of used machines to the professional
execution of their repair in accordance with the
individual specifications of the customer.

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52

TRANSFER OF TECHNOLOGY

BROAD SERVICE SPECTRUM The BBM Group is active in a variety of future-orientated business areas:
Our core business comprises mining, structural, underground and civil engineering as well as assembly. In addition,
as an innovative company we have also embarked on the development and marketing of new IT technologies. Our
services at a glance:

CONTACT:
Operta-BBM

Dieter-aus-dem-Siepen-Platz 1
D-45468 Mlheim an der Ruhr
PHONE +49 (0) 208 459 59-0
FAX +49 (0) 208 459 59-59
EMAIL info@operta-bbm.de

OPEN CAST MINING


Excellent raw materials for successful construction projects Our quarries produce first-class
rock for structural and civil engineering. Our stone fractions, high quality fine flints and architectural stone are used primarily in road construction and concrete production, and also in
the chemical industry. BBM is also increasing in demand as a contract mining supplier for raw
materials extraction.
MINING
Top quality services based on experience BBM is an outstanding supplier of specialist underground mining services, in particular in Germany. Working on behalf of large mining companies, we assume responsibility of complete lots or provide personnel for all forms of mining
and assembly work. Our teams are available for flexible application right across Europe. Our
own workshop maintains our fleet of machines. BBM has also succeeded in making a name for
itself as a contract mining supplier in the underground mining sector.

DIVERSE ACTIVITIES ACROSS EUROPE The proprietor-managed BBM Group has enjoyed success on the market since 1990 and is active in a wide range
of business areas. Networked with internationally renowned cooperative partners, we support demanding projects throughout Europe. In doing
so we apply the skills of around 1,000 highly qualified employees, who work with competence and commitment to ensure the seamless fulfilment
of our orders. It is with maximum flexibility that we set benchmarks in quality and reliability. Thanks to rapid decision-making and the central
steering of all activities, we offer integrated solutions from a single source and generate tailored solutions in all business sectors.

W W W. O P E RTA - B B M . D E
Issue 01 | 2013

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WE BUILD THE FUTURE Every project needs a vision and the resources to transform it into reality. BBM combines both: Top quality demands throughout all of our activities in a wide range of areas, excellent corporate knowhow and expert knowledge of the skilled trades and technology. This
results in excellent products and services, for which we are renowned and valued right across Europe. BBM is a reliable and in-demand partner, greatly trusted by its clients and cooperative partners. This high performance level and consistent orientation towards the demands of our
customers makes us exceptional. We accept challenges and create added value: As a dynamic company that will continue to grow in the future
and tap into new markets across Europe. BBM brings projects to a successful conclusion take our word for it and profit from our rich wealth
of experience.

53

TRANSFER OF TECHNOLOGY

Thyssen Krupp:

Modern gearless drive systems for


high-capacity belt conveyors
Gnther Kerkhoff | BSEE General Manager Electrical | ThyssenKrupp Robins Inc. | Denver | USA
Dipl.-Ing. Peter Sehl | General Manager Sales & Service | ThyssenKrupp Robins Inc. | Denver | USA
Vladimir Svirsky | MSME Chief Mechanical Engineer | ThyssenKrupp Robins Inc. | Denver | USA

n many mining areas, ore grades are declining. New mines are being developed in ever
more remote areas. Pits are getting deeper and more hard-rock mines are switching to
underground operations. This means that more material must be transported over longer
distances, which creates new challenges. As mining volumes increase, demands for
availability are also rising. As a result, conveying systems need to be equipped with modern
drive systems that guarantee a high degree of reliability.

Gearless drive system, 2 x 3,800 kW, 63 rpm, 631 kNm

Issue 01 | 2013

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54

TRANSFER OF TECHNOLOGY

Partnership with Siemens for large


conveying systems

Gearless drive characteristics and


advantages

For many years ThyssenKrupp and Siemens have


partnered to help build some of the most impressive
conveyor systems in the mining industry. One of the
greatest success stories is the Los Pelambres downhill
conveyor in Chile, installed in 1999, which is the highest
tension conveyor belt in the world. It transports copper
ore over a distance of 12.7 kilometers from 3,200 meters
above sea level down to 1,600 meters and in so doing
generates up to 17 MW of electrical energy, which is
fed into the grid.

Gearless drives are an attractive alternative for


conveyors with higher power requirements. Due
to their simple construction, such drives offer very
high availability, robustness, reduced operating and
maintenance costs, and reduced noise as well as the
benefits of a variable-speed drive.

Technical limits of conventional drive


systems
The gear reducers traditionally used to drive conveyors
reach their physical limits in demanding applications,
such as steep-angle or high-capacity installations. For
example, a modern conveyor system with a total drive
power demand of 20,000 kW requires at least eight
traditional gear reducer drives, each equipped with
2,500 kW motors.

With gearless drive systems, a slow-running


synchronous motor is directly connected to the shaft of
the drive pulley. Because of the slow motor speed, no
gear reducer is required. The rotor of the synchronous
motor / Fig. 1 / is flanged onto the pulley shaft.
Gearless drive technology is nothing new to the
mining business. Mining companies have been
installing high power gearless drives for mine hoists,
excavators, draglines, pumps and mill applications
for many years. While the technology is similar, the
requirements differ for conveyor applications. Similar
to mills, conveyors require a lot of torque during startup, especially in uphill applications. Gearless drives
increase operating efficiency while at the same
time providing high reliability and low maintenance
requirements:

The traditional gear reducer solution has the


disadvantage of reduced overall availability associated
with the large number of mechanical components (e.g.
more than 70 bearings for eight 2,500 kW gearboxes)
which results in a lower mean time between failures
(MTBF).

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TRANSFER OF TECHNOLOGY
Fig. 1:
Gearless drive rotor during shop
inspection at Siemens

For the previous 20,000 kW example, a gearless


drive solution can be accomplished with only 3 or 4 low
speed motors and no bearings or couplings. With fewer
components, the drive station and electrical building
require a smaller footprint / Fig. 2 /. This is especially
beneficial for underground applications where the
number of expensive excavations for drive stations is
minimized.
For downhill operation, the drives are able to work in
regenerative mode and supply the mine operation with
additional electrical energy. Advances in conveyor belt
technology are also supporting the capabilities offered
by gearless drive systems. Newly developed stronger

belts (ST-10000) are now available that can withstand


the higher stresses resulting from increased drive
power requirements.
Mining companies are striving to reduce energy
consumption and CO2 emissions and increase system
reliability. Gearless drives meet these requirements
by significantly reducing the number of mechanical
components, such as gears, bearings and couplings,
while delivering higher efficiency / Fig. 3 /. The capital
expenditure for a gearless drive conveyor is equal to or
less than that for conventional geared drives, especially
if capital spare parts are a consideration.

Fig. 2:
Reduced footprint of
gearless drive system
(motor on left is shown in
maintenance position with
the stator housing moved
away)

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56

TRANSFER OF TECHNOLOGY
Fig. 3:
Comparison of standard vs. gearless
drive solution

First reference for gearless drives


in German coal mine
In 1985, O&K (now part of ThyssenKrupp)
and Siemens installed the first gearless directdrive belt conveyor with cycloconverterfed synchronous motors. Engineers at RAG
Deutsche Steinkohle were impressed by the
converter technology and decided to use it in
the underground Prosper-Haniel coal mine in
Germany / Fig. 4 /. More than a quarter century
later, the belt drives are still in operation to the
complete satisfaction of the mine. The conveyor
system provides an availability of more than 99%.

Managers at RAG indicate that:


There have been no significant interruptions or


failures attributable to motors and converters.

Maintenance costs are significantly lower than for


conveyor drives with gearboxes.

Estimated electrical energy savings of 10% are


achieved annually compared to fixed-speed geardriven drive arrangements.

New gearless drive system


for client in Peru
Continuing their successful teamwork, ThyssenKrupp
Robins and Siemens are now delivering an overland
conveyor to Xstrata Coppers new Antapaccay mine in
Peru with a gearless drive system / Fig. 5 /. The conveyor
system will transport ore over a distance of some 6.5
kilometers from the mine to the processing plant on a
1,370 mm wide belt travelling at 6.2
meters/second.

Fig. 4:
Prosper Haniel mine, conveyor drive station with
gearless drive system, 2 x 3,100 kW

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TRANSFER OF TECHNOLOGY

When the belt conveyer system is commissioned in


2012, it will be capable of transporting up to 5,260 tons of
copper ore per hour. The drive system comprises two lowspeed synchronous motors each with a rated power
output of 3,800 kW and the associated cycloconverters,
motor cooling systems, converter transformers and
complete electrical house for the drive station. A closed
loop control system improves load sharing between the
two motors.

Summary
Long conveyors with large throughputs and/or high
lifts require a significant amount of power. When the
demand for power exceeds 3 MW per pulley, gearless
drives for the conveyor become the preferred solution.
Gearless drive solutions provide many benefits
compared to gearreducer drive systems:

Higher plant availability by eliminating electrical


components, couplings, bearings and gearboxes
therefore minimizing the risk of downtime;

Up to 4% higher energy efficiency achievable with


gearless direct-drive technology;

Longer conveyors with fewer drive stations and


smaller footprints resulting in less excavation for
underground applications;

Higher available power at the pulley;

Issue 01 | 2013

Fig. 5:
Rendering of a drive station for the Xstrata
Copper Antapaccay mine in Peru

Reduced maintenance achieved by reducing the


potential for mechanical breakdowns through the use
of robust components;

Fewer spare parts resulting in lower inventories and


lower investment costs;

Reduction in noise levels achieved by eliminating the


gear reducers, which are the noisiest component in a
traditional drive system.

The mining industry, particularly in South America, is


looking increasingly at large, high-capacity conveyors
as a solution to meet ore and overburden transportation
requirements.
Gearless drive solutions have the potential to
meet these new requirements efficiently and at lower
operating costs.

FOR MORE INFORMATION AND CONTACT:

ThyssenKrupp AG
ThyssenKrupp Allee 1
D-45143 Essen
Tel.: +49(0) 201 844 0
Fax: +49(0) 201 844 536000
E-Mail: info@thyssenkrupp.com
Internet: www.thyssenkrupp.com

www.advanced-mining.com

58

TRANSFER OF TECHNOLOGY

Innovative and Efficient Solutions


for challenging tasks in extraction, surface mining and surface forming.

T1255 Terrain Leveler

Vermeer has transcribed its long-standing


experience in the area of rock mills into its new
surface mill.
The T1255 is characterized by protected technology, intelligent design, excellent production and system stability.
Meanwhile the Terrain Leveler can process an
area of up to 3.7 m width and 61 cm depth in
one single run.

The machine has been designed to ablate all


kinds of rocks, gypsum, coal and other material (e.g. concrete). This is done using a big,
hydrostatically steered milling drum, which
ablates the rock in a more efficient way and
with a higher cutting depth.
The result:
More coarse material with a low proportion of
fine fraction.

www.vermeer.de
Deutschland GmbH
Puscherstr. 9
90411 Nuremberg, Germany

Issue 01 | 2013

Tel.: +49 (0) 911 5 40 14 0


Fax: +49 (0) 911 5 40 14 99

ANZEIGE
ADVERTISEMENT
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59

NEWS & REPORTS


Fig. 1:
The HRC is ideal for high-tonnage, hard rock applications and can be used as
a tertiary, quaternary or pebble crusher. The machine does have range within
hard rock applications: its been designed for use in diamond, iron ore, copper,
gold, platinum and various industrial minerals.

Metso Minerals (Deutschland) GmbH


Bochum | Germany

Metsos HRC takes

high pressure grinding roll technology


to the next level

etsos latest development in comminution equipment, the HRC, is a major step in the
profitable application of high pressure grinding roll (HPGR) technology. Metso has made
M
several key innovations in order to increase throughput and decrease total cost of operation.

Patented Arch-frame eliminates


downtime caused by skewing

Flanges maximize wear life and increase


throughput

Metsos patented Arch-frame creates an even gap


setting across the width of the tires, limiting skewing that
can result in downtime for mining operations. This antiskewing Arch-frame also prevents damage to the roller
bearings (caused by misalignment) that can occur with the
traditional HPGR design.

Used in place of spring-loaded cheek plates, the flanges


keep the bed of material within the crushing zone and
prevent material from bypassing the tires. This enables
greater circuit capacity and increases the overall crushing
efficiency.

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NEWS & REPORTS


In addition, by preventing material from bypassing the
tires, even pressure across the width of the tire is better
maintained. By distributing the pressure more evenly, the
tire life is maximized by preventing a bath tub effect, in
which the center of the tire wears faster than the edges.
Victoria Herman, Metsos product manager for the HRC,
notes that this breakthrough design is a response to the
growing needs in the mining industry. Energy efficiency
has been attracting our customers to HPGR technology
for years, she says. But (our design concept) increases
capacity and crushing efficiency and thats something
mining companies are always looking to improve on.

Other notable benefits of the HRC


Hydraulic cylinders are positioned to create a compact


design while still providing excellent crushing strength

Dust enclosure minimizes dust and reduces noise

Transporter facilites a safe and fast tire replacement

Feed hopper include liners designed for long life

Studded tires maximize tire life by building up an


autogenous layer

The HRC is ideal for high-tonnage, hard rock applications


and can be used as a tertiary, quaternary or pebble crusher.
Currently, several HRC units are in operation around the
world with a total of 6,500 operating hours including
over 3,800 hours in a mining hard rock application. The
machine does have range within hard rock applications:
its been designed for use in diamond, iron ore, copper,
gold, platinum and various industrial minerals.

Mining and Construction


Metsos mining and construction professionals specialize
in always bringing the right technology, processes, machinery
and services to our customers in the aggregates production,
construction, mining and minerals processing.

www.metso.com/miningandconstruction

Metso
Metso is a global supplier of technology and services
to customers in the process industries, including mining,
construction, pulp and paper, power, and oil and gas. Our
30,000 professionals based in over 50 countries deliver
sustainability and profitability to customers worldwide.
Expect results.

www.metso.com

Fig .2:
Currently, several HRC units are in operation around the
world with a total of 6,500 operating hours including over
3,800 hours in a mining hard rock application.

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NEWS & REPORTS


Improtant test results:
Basalt:

Crushability - 28,13% (Macon)


P50/F50 - 6x (Hydraulic Cylinder Pressure: 75 bar - Specific Crushing Pressure:
2,0 N/mm2)

Diabase

Crushability - 30,09% (Macon)


P50/F50 - 3,5x to 6,0x according to the size feed (Hydraulic Cylinder Pressure:
90 bar - Specific Crushing Pressure: 2,0 N/mm2)

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NEWS & REPORTS


Granite

Crushability - 51,91% (Macon)


P50/F50 - 6,0x (Hydraulic Cylinder Pressure: 160 bar - Specific Crushing
Pressure: 4,0 N/mm2)

Limestone

Crushability - 41,99% (Macon)


P50/F50 - 10x (Hydraulic Cylinder Pressure: 80 bar Specific Crushing Pressure: 2,7 N/mm2)

River Pebbles

Crushability - 53,26% (Macon)


P50/F50 - 5,5x (Hydraulic Cylinder Pressure: 120 bar Specific Crushing Pressure: 3,0 N/mm2)

FOR MORE INFORMATION AND CONTACT:

Metso Minerals
Mrs. Victoria Herman,
Product Manager, Hydraulic Roll Crushers
Tel.: +1 717 849 7241 | Mobile: +1 717 309 1150
eMail: victoria.herman@metso.com
Internet: www.metsominerals.com

Issue 01 | 2013

Metso Minerals (Germany) GmbH


Kantstrasse 22-24
D-44867 Bochum
Uwe Kahlert
Mobil: +49(0) 1776608489
eMail: uwe.kahlert@metso.com
Internet: www.metso-deutschland.de

www.advanced-mining.com

63

NEWS & REPORTS


Sandvik Construction

Sandvik Mobile Crushers and Screens

unveil two new models at Bauma 2013

Sandvik Construction Mobile Crushers and Screens will be using the showcase
of Bauma 2013 to officially launch two new additions to their advanced product
offering, thereby demonstrating continuous commitment to new product
development. Sandviks dedicated R&D team have been working hard over the
past couple of years to design customer-focused solutions which are easy to
operate, and more efficient to run, whilst maintaining the high standard of quality
whilst adhering to the latest safety directives.

New heavy-duty scalper for increased


performance and productivity
The latest incarnation of the original E7 mobile
scalper demonstrates the value of customer feedback
and experience, as the new model contains a wish
list of features and benefits that far exceed traditional
expectations of durability and technical excellence.
Customer requirements which have been met with the new
model include:
E
normous increase in stockpiling capacity
Wider oversize conveyor to handle larger material
Heavy duty apron feeder with increased feed hopper
size
Aggressive screen box action to maximize enhanced
product handling and delivery capability
User friendly color-coded control panel with sequential
start for ease of operation.

Issue 01 | 2013

New Impactor model for premium


productivity and performance whatever
the application
Also being showcased for the first time on the
international stage will be a new Impactor model which
will further enhance Sandviks extensive crusher portfolio.
Featuring Sandviks market leading Impactor technology,
this new model will offer customers unparalleled flexibility
in primary and secondary applications, undoubtedly
proving to be the perfect solution for large scale operators.
This new model will possess many customer benefits such
as:
Large feed hopper with highly efficient pre-screening
Underpan feeder to reduce any spillage issues and
protect the main product conveyor from high velocity
material from the rotor
Excellent reduction ratio with impressive rates of

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64

NEWS & REPORTS


production
User friendly PLC control system and color screen for
ease of operation
Low wear, easy maintenance and a low cost per ton.

The versatility of the equipment is ensured by a


comprehensive range of optional extras that allows
the right crusher to precisely match the demands of the
customers specific application. These include an optional
double deck hanging screen with recirculation system,
which will allow the crusher to produce accurately sized
products for immediate use at source.
The two new additions to the range have been designed
with mobility, productivity, transportability and user
friendliness at their core, but with a level of customer
involvement unprecedented within the industry. Both units
are fitted with radio remote control as standard, and are
fully compliant with the latest Machinery Directives.

For further information please contact:


Sandvik Construction
Melissa Baker, Marketing Communications
Mobile Crushers and Screeners
Tel. +44(0) 1283 212121
eMail: melissa.baker@sandvik.com

Sandvik is a global industrial group with advanced


products and world-leading positions in selected
areas tools for metal cutting, equipment and tools
for the mining and construction industries, stainless
materials, special alloys, metallic and ceramic
resistance materials as well as process systems.
In 2011 the Group had about 50,000 employees and
representation in 130 countries, with annual sales of
more than 94,000 MSEK.
Sandvik Construction is a business area within
the Sandvik Group providing solutions for virtually
any construction industry application encompassing
such diverse businesses as surface rock quarrying,
tunneling, excavation, demolition, road building,
recycling and civil engineering. The range of
products includes rock tools, drilling rigs, breakers,
bulk-materials handling and crushing and screening
machinery. In 2011 sales amounted to more than
9,000 MSEK, with approximately 2,600 employees
(pro forma rounded numbers).

Pic:
Sandvik QA450 in action

Issue 01 | 2013

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NEWS & REPORTS


Sandvik Mining and Construction

Sandvik DC125R

Functional simplicity and nimble mobility


SSandvik DC125R shows what it means when function
truly meets form. It is a new member to the proven, highquality Sandvik DC family of compact, rubber-tyred top
hammer drill rigs. The model carries all familiar handy
features that simplify the everyday life of a job site,
and includes a bunch of new ones resulting in top-rate
mobility, great serviceability, low fuel consumption and
an absolutely attractive outlook.

Sandvik DC125R: Functional simplicity and


nimble mobility
Sandvik DC125R is a fully remote-controlled, hydraulic and selfpropelled mini-sized drilling unit on a 4-wheel drive carrier, for
drilling of 22 45 mm holes. The new model replaces the former
Sandvik DC122R, one in the series of rigs originally launched in
1988 under the product name of Tamrock Commando.

A range of job site tests show that the new


model, the Sandvik DC125R, offers better
maneuverability than ever before. This is thanks
to the new large drive gears that make the rig
invincibly nimble and mobile, guaranteeing
safety of operation even in the most difficult
ground conditions. Rough terrain safety is
further enhanced by a new winch with rollertype of rope guides.

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NEWS & REPORTS


Thanks to its simplified body structure, easily
interchangeable drive gears and a new type of simplestructured dust collector, the rig is easy to maintain.
Further adding to the user-friendliness of the rig are
centralized oil changing spot, straightforward hose
routing and electrical component center.
A new cooling system keeps the rig running smoothly,
and an externally placed silencer reduces the heat load
in the engine compartment. An ambient temperaturecontrolled cooling fan brings considerable savings in
fuel consumption.
New covers and a refreshed design give the rig an
appealing outlook, and six working lights guarantee
visibility during the dark hours as well.
The mini-sized Sandvik DC125R mini rig is at its best
in applications such as foundation drilling, road cutting,
trenching, bolting, line drilling in dimensional stone
quarries, and other special drilling applications.

Sandvik Construction
Nina Lehtonen
Marketing Communications,
Surface Drilling and Tunneling
Tel. +358 400 534 344
eMail: nina.lehtonen@sandvik.com

The Sandvik-Group

Table:
Sandvik DC125R

Hole diameter
Rock drill
Engine output
Flushing air
Production capacity
Total weight

Contact:

22 - 45 mm
5,5 kW
37 kW
1.2 m3/min, up to 8 bar
300 400 m3/8 h
3 150 kg

Sandvik is a global industrial group with advanced


products and world-leading positions in selected
areas tools for metal cutting, equipment and tools
for the mining and construction industries, stainless
materials, special alloys, metallic and ceramic
resistance materials as well as process systems.
In 2011 the Group had about 50,000 employees and
representation in 130 countries, with annual sales
of more than 94,000 MSEK.

Sandvik Construction
Sandvik Construction is a business area within
the Sandvik Group providing solutions for virtually
any construction industry application encompassing
such diverse businesses as surface rock quarrying,
tunneling, excavation, demolition, road building,
recycling and civil engineering. The range of
products includes rock tools, drilling rigs, breakers,
bulk-materials handling and crushing and screening
machinery. In 2011 sales amounted to more than
9,000 MSEK, with approximately 2,600 employees
(pro forma rounded numbers).

Issue 01 | 2013

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NEWS & REPORTS


Sandvik Construction

One crusher, two configurations

Sandviks New Prisec TM CI5** Series HSI

he new generation of compact horizontal impact crushers (HSI) from Sandvik provides customers
with a low capital cost solution, optimum performance and good cubical shape, whilst ensuring the
lowest operating cost per ton for a wide range of materials and applications. The all new patented and
highly modularized Sandvik CI5** Prisec TM crusher range, additionally combines the ability to configure
one base crusher into either a Primary or a Secondary configuration, thereby making it adaptable to everchanging requirements.
The new Horizontal Shaft Impactor (HSI) range
of crushers from Sandvik Construction have been
developed in response to customer demands, building on
the rock solid foundation of the primary and secondary
series they will replace. Spearheaded by the CI511, this
new range of crushers establish Sandvik as market
leaders in the design and development of HSI crushers
that have been developed to deliver exceptional rates
of productivity and efficiency. All crushers possess the
ability to be configured into either a primary or secondary
crusher operating mode and with this unique, exclusive
to Sandvik, patented design, provides customers with
unparalleled adaptability.

Issue 01 | 2013

Exceptional reduction ratios


Sandviks revolutionary all new design of crushing
chamber ensures even greater reduction ratios than
have been previously obtainable. Furthermore the
Prisec TM crusher is able to easily produce impressive
reduction ratios through the use of two uniquely
designed curtains, which have traditionally required
a three curtain configuration crusher. As well as
enhanced productivity, this means fewer wear parts
and reduced maintenance.

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NEWS & REPORTS


Energy efficient overload protection

Dealing with crusher blockages

DThe CI511 Prisec TM is equipped with an infinite


hydraulic curtain adjustment combined with a brake
positioning system which relieves pressure, and
setting, when un-crushable objects enter the crusher.
No hydraulic power is required during normal operation,
thus saving on operating power and reducing total
power consumption. Both first and second curtains
are infinitely adjustable via the Sandviks patented
adjustment / braking system which is located on the
cross beams of the crusher. This system gives hydraulic
adjustment of both curtains, via the standard supply
electric hydraulic power pack.

Crusher blockages have always historically been


a problem, especially when operating in a primary
configuration. Removal of the blockage, with the
combined downtime and health and safety risks
encountered, are now eliminated with the Sandvik new
generation Prisec TM crusher. Due to the exceptional
features of the crushers no stopping of the crusher is
necessary, with no operator intervention inside the
crusher, no heavy lifting gear required, all resulting
in maximum uptime and reduced health and safety
problems.

Rotor and hammer


design
The rotor and hammers can
be considered as the heart of the
crusher; this is why those used on
the CI5** Prisec TM
range are
both robust and efficient. Rotors
have superior weight and design,
essential for delivering the high
inertia required for optimum crusher
performance, thus ensuring stability
and smooth operation during
production. The unique banana
shaped self-sharpening hammer
design helps to keep the contact
heads sharper during operation,
resulting in more effective shearing
of the incoming material, and hence
improved production.

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NEWS & REPORTS


Easy and Safe maintenance
A unique key safety interlock system ensures safe
maintenance of the crusher and prevents accidental
opening of the crusher and inspection doors even in
multiple installations. It also allows the ability to raise
curtains during operation without stopping the crusher
to clear blockages, and re-set automatically to operating
setting. This maximizes uptime and reduces the need
for heavy lifting gear and operator / maintenance
intervention, thereby reducing further Health & Safety
risks.

Maximum uptime, Maximum breakage


Through the modularized nature of the Prisec TM
range, wear parts can be turned for maximum life/
usage with the same size being used across the whole
range of crushers. In addition, Sandviks world leading
technology in the hammer and liner material composition
provides options far surpassing old industry standard of
manganese, resulting in even lower operating cost per
ton and the ability to operate efficiently in a variety of
materials, especially recycling applications.

Contact:

Sandvik Construction
Rowan Dallimore
Sandvik Construction
Product Manager Impact Crushers
Stationary Crushing and Screening
Tel: +44(0) 1761 239249
eMail: rowan.dallimore@sandvik.com

Table:
Sandvik Cl511 PrisecTM crusher

Technical Data
Rotor diameter (mm)
Max. feed size (mm)
Rotor configuration
Tonnage throughput (nominal)
Tonnage throughput (nominal)

Issue 01 | 2013

CI511 Prisec TM crusher


1005mm High x 950mm wide
600mm
Open Type, 4 hammer.
200 TPH
200 TPH

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Sandvik Construction Central Europe

New Alpha 330 drilling tool system


signals a new era of rock tool economy through increased
rod life, more accurate collarings and straighter blastholes

In order to match the increased energy output from modern high power rock drills
now used in drilling and tunneling, Sandvik Construction is proud to launch the
Alpha 330 drilling tool system. This advanced system has been developed with
special features that control power and, most importantly, ensure that this power
is transmitted into the rock as efficiently, accurately and economically as possible.
In tests, in varying rock conditions, the new design has been proven to deliver a
30-80% increase in rod life, provide more accurate collaring and straighter blastholes, thereby delivering greater advancement, improved profile control, thus
enabling projects to be completed more rapidly, as well as reducing the overall
cost of drilling and tunneling.

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NEWS & REPORTS


The Sandvik Alpha 330 has been designed and
dimensionally optimized to replace the R32 connections,
which until now has been the dominant 45 mm system.
A key development of this advanced new system
sees the drill string rod / bit connection featuring an
entirely new thread design. Furthermore the Alpha 330
possesses a shorter thread on the hexagonal rods in
the tool system resulting in a rigid, integrated powerpack drill string, which possesses superior resistance
to bending stresses, thereby securing perfect energy
transfer. As part of the manufacturing process more
steel has been used for higher fatigue strength, which
further helps ensure exact collaring and straighter
holes, as well as delivering a 30-80% increase in rod
life.

Designed to boost productivity


Essentially the Sandvik Alpha 330 system has been
designed to increase customer productivity; it is able
to accomplish this due to inherent benefits derived
from the stronger and more rigid R33 thread, which
possesses a significantly larger cross-section than
R32, thereby making it proportionately stronger. Further
improving rigidity, the Alpha 330 possesses a new
guiding function located between the rod and bit-skirt
immediately behind the thread. This means that the rod
cross-section over the guide is now 36% larger (Alpha
vs. R32) at the rear of the connection, greatly improving

Issue 01 | 2013

the rigidity of the joint. After the bit-skirt, the rod crosssection increases to Hex-35 quickly, and smoothly,
ensuring that the sturdy thread is well guided inside the
bit-skirt, offering higher precision in collaring even in
complex rock formations and uneven surfaces.

Customer satisfaction
The reported benefits customers have experienced
from using the Sandvik Alpha 330 tool system in global
tunneling projects has been staggering: rod life has been
extended by at least 30%; as well longer shank adaptor
and coupling life spans. These factors alone have seen a
reduction in total drilling tool cost by 20%, with additional
benefits including high rates of penetration, advanced
precision in collaring, superior drilling accuracy, faster
and easier uncoupling of bits, as well as reduced machine
downtime. Furthermore, the hard wearing and productive
features inherent to the Alpha 330 has enabled tunneling
projects to be completed in less time.

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Summary of key features of the
Alpha 330
New Short thread design and hexagonal
rods result in a rigid, integrated drill string
optimized for 43-51 mm drilling.
The new short thread design offers increased
precision in collaring.
A rigid drill string results in straighter holes,
permitting optimum drilling patterns, better
hole accuracy and higher rates of advance.
Exact collaring and straighter holes (essentials
for productive drilling) are assured with less
over-break and lower overall costs.
Less downtime of machinery resulting in better
scheduling through optimal productivity.

The new Alpha 330 from Sandvik


Construction is the latest addition to Sandviks
world leading rock tools range of products
that are aimed at enhancing customers
productivity, and efficiency, whilst reducing
the overall costs of drilling and tunneling.

Contact:

Sandvik is a global industrial group with advanced


products and world-leading positions in selected areas
tools for metal cutting, equipment and tools for the
mining and construction industries, stainless materials,
special alloys, metallic and ceramic resistance materials
as well as process systems. In 2011 the Group had about
50,000 employees and representation in 130 countries,
with annual sales of more than 94,000 MSEK.

Issue 01 | 2013

Sandvik Construction
Emilie El Tarzi
Marketing Communications Specialist
Tel: +46 (0) 26 26 23 26
eMail: emilie.eltarzi@sandvik.com

Sandvik Construction is a business area within the


Sandvik Group providing solutions for virtually any
construction industry application encompassing such
diverse businesses as surface rock quarrying, tunneling,
excavation, demolition, road building, recycling and
civil engineering. The range of products includes rock
tools, drilling rigs, breakers, bulk-materials handling
and crushing and screening machinery. In 2011 sales
amounted to more than 9,000 MSEK, with approximately
2,600 employees (pro forma rounded numbers).

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SBM Mineral Processing GmbH

PREMIERE: First Presentation of the New


REMAX 1112 MAXI to the Expert Audience!

New mobile mineral processing plant from SBM: The new plant REMAX 1112 MAXI
offers a completely redesigned material flow. Image: REMAX 1312 MAXI. SBM

First Presentation of the New


REMAX 1112 MAXI to the Expert Audience
In time for the bauma 2013, SBM launches a new mobile
mineral processing plant and expands the REMAX series
by a powerful, economic plant. With 41 tons this mobile
track-mounted plant belongs to the mediumsize class
of the REMAX series. The new plant REMAX 1112 MAXI
offers a completely redesigned material flow making
material jamming a thing of the past. The discharge
conveyor belt below the screen can be optionally fixed or
swivelling by 180 increasing stockpile capacity fivefold
and considerable improving logistic processes.
The impact crusher RHS ensures proven quality made
by SBM. The rotor with a diameter of 1160 mm provides a
very high energy level in the crushing chamber. Uniform
crushing capacity and high throughput capacity are
convincing performance parameters of the plant made
by SBM. The diesel-electric drive system ensures low
operating costs. REMAX 1112 MAXI is also equipped with
a change-over switch for generator or mains operation

Issue 01 | 2013

further reducing operational costs. Additional features of


the new SBM plant are a rotor with adjustable speed and
a mounted cleaning function of the discharge chute. This
plant is supplied with a frequency converter to control the
speed of the return conveyor of the oversize material.
Dolly-compatible compact transport dimensions and
fulfilling latest environmental standards go without saying.
Additional improvements include a revised control concept
offering simplified operation as well as automatic feed
hopper locking making the REMAX 1112 MAXI a state-ofthe-art plant concerning safety specifications. The graphic
scratch-proof touch display ensures easy operation of the
plant with gloves. A new feature of the REMAX series is a
radio control permitting simple manoeuvring of the plant,
operating the magnetic separator, and adjusting the feed.
Additional functions are available upon request.

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EXPANSION OF PRODUCT PORTFOLIO:
Reclaimer an Economic Power
Package for Homogenised Bulk Materials
By developing a highly efficient reclaimer - a bridge type
bucket wheel reclaimer - SBM Mineral Processing GmbH
expands its product portfolio especially for processed
bulk materials. This new product made by SBM is applied
wherever economic handling and homogenisation of large
volumes of bulk material are of paramount importance
i.e. a plant especially targeted on the demands of
the extractive industry. This type of reclaimer features
exceptionally high loading capacity and high availability.
It is especially designed for extreme operating conditions
such as ice, snow and frost.
A distributing conveyor puts the processed material with
a grain size of 0-8 mm in layers on two stockpiles. Then the
material is fully automated reclaimed by the reclaimer and
fed to the loading of wagons by means of conveyors. The
SBM reclaimer stockpiles 1000 t/h at a rail gauge of 58 m
and will start operation in autumn 2013. This new product
development is an essential part of a major order SBM - an
Austrian company with long-standing tradition - managed
to obtain last year.
By expanding the product portfolio in the direction of
handling bulk materials for mining, port facilities and steel
works industries, SBM intends to open up new customer
segments. The Austrian high-quality manufacturer
possesses decades of know-how in process engineering
and convinces thanks to worldwide
reference projects for industrial
plant engineering under extreme
weather conditions.

Issue 01 | 2013

FOR MORE INFORMATION AND CONTACT:


SBM Mineral Processing GmbH
Mag. Alexandra Wagner, Leitung Marketing
Oberweis 401 | 4664 Oberweis, Austria
Tel.: +43(0) 3612/270-1510
Mobil: +43(0) 676/8827-1510
eMail: a.wagner@mfl.at
Internet: www.sbm-mp.at

SBM Mineral Processing GmbH


For more than 60 years, SBM Mineral Processing
has specialised in mineral processing plants and
conveying plants for natural stone and recycling
industries. In the mineral processing field, SBM
carries the brands SBM and MFL. The second product
field of the Austrian high-quality manufacturer are
concrete mixing plants fulfilling all requirements
on international concrete standards. SBM and its
130 employees belong to the MFL Corporate group
operating all over the world.

New mobile mineral processing plant from SBM: The new


plant REMAX 1112 MAXI offers a completely redesigned
material flow. Image: REMAX 1312 MAXI. SBM

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NEWS & REPORTS


Allmineral Aufbereitungstechnik GmbH & Co. KG

Global Player from Duisburg at Bauma 2013:


For 25 years, allmineral supplies innovative
processing technology increasingly in
demand throughout the world

allmineral: sishen

From copper processing in Queensland, Australia, to sorting hematite iron


ore in Brazils Iron Quadrangle, from jigging machines in the Pilbara
region to magnetic separators in the Indian Sarda mines: allminerals
innovative solutions play a key role in the state of the art processing
of raw materials around the world. Visit us and find out more about
the latest development in beneficiation applications, related processes
and machinery at the BAUMA 2013 (Hall B2, Booth 319/414, Hazemag Group
corporate booth).

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Supported by its numerous international affiliates
and selected partners allmineral supplied processing
plants into the most important raw materials markets
in the world. In these plants the systems are the key
technology for the efficient and economical processing
of ores, coal, gravel, sand, metal slag and a variety of
recyclable materials.
And whats more: as a member of the renowned
Hazemag Group, allmineral has expanded its
international network yet again and can provide an
even better service to its customers by way of global
collaboration with Hazemag companies and partners.
The Hazemag Groups involvement is another
example of our successful and consistent marketing
strategy focused on the global marketplace, says
allminerals CEO Dr. Ing. Heribert Breuer about the
new partnership. The international market has
grown significantly for our mainstay in ore and
coal processing. The company has established a
sustainable global presence and as a group we will be
able to offer to our customers an even larger range of
products and expertise.

allminerals latest start-up, allmineral Australia Pty.


Limited contributes to strengthening allminerals position
in the booming Australian market a market that still
has enormous potential. In addition to the successful
commissioning of Rio Tintos strategically crucial pilot
plant including alljig, allflux and gaustec-WHIMS
as the core components, allmineral secured more
orders in the Pilbara area. By the end of 2012, there
were a total of 17 alljigs and 25 allflux in operation
in Australia.

allminerals latest achievement on the


fifth continent was in Queensland:
The up-and-coming Australian mine operator CUDECO
is banking on the innovative Duisburg technology for
its native copper processing. Under the direction of
the Chinese state-owned enterprise SINOSTEEL in
mid-2013, a total of ten alljigs will be installed for
the beneficiation of various grain sizes as part of the
ambitious Rocklands Group Copper Project.

allmineral: christmas creek

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This allmineral technology is used by a number of
leading mining companies around the world and is
the key component of this modern, high tech plant
that will not only produce copper concentrate, but
also cobalt, gold, pyrite and magnetite concentrates
in the course of the next decades.
The first of the latest generation of magnetic
separators have raised the bar in Brazil and India
for hematite iron ore processing, by doubling the
throughput rate to 700 tph. Despite this increase
in capacity, the new design allows for keeping the
gaustec-GX WHIMS dimensions, weight and
energy consumption at approximately the same level
compared to smaller units.. As a direct result capital
expenditure and operating costs per ton of feed are
significantly lower, also thanks to the fact that the
gaustec-GXs innovative technology requires less
equipment in the field and allows for a simplified
process flow.

FOR MORE INFORMATION AND CONTACT:


allmineral
Aufbereitungstechnik GmbH & Co. KG
Baumstrae 45
47198 Duisburg | Germany
Tel.: +49 (0)20 66 - 99 17 - 0
Fax: +49 (0)20 66 - 99 17 - 17
eMail: head@allmineral.com
Internet: www.allmineral.com

allminerals success story continues in other


areas as well for example, with the alljig-GR
jigging machines for processing and cleaning coarse
fractions of up to 80 mm particle size. In only four
years, there have been 40 successful jig installations
with this new discharge arrangement in the gravel,
sand, ore and recycling sectors.
With its innovative alljig, allair, allflux und
gaustec systems, allmineral has been successful
in the market for over 25 years now, and is the
right partner to talk to in regard to separation and
processing of coal, ore, slag, gravel and sand or
for recycling (of construction waste, for example).
allminerals plants are in Europe, India, Australia,
North and South America as well as in South Africa.
Around the world there are more than 750 allmineral
plants in operation, reliably and efficiently applying
both methods, dry and wet.

About allmineral

Bauma 2013:
allmineral is at the Hazemag Groups corporate
booth | Hall B2, Booth 319/414

Issue 01 | 2013

allmineral is a world-renowned specialist in the


preparation of gravel, sand, coal, slag and ore. Our
system solutions are oriented to the individual needs
of our customers, market conditions and the quality of
the raw materials available. In close cooperation with
our customers, our qualified staff develops an optimal
concept, builds the appropriate system and ensures
trouble-free operation..

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NEWS & REPORTS


The new mobile jaw crushers from
Kleemann: Mobicat MC 110 EVO.

Kleemann GmbH

Global innovation in the Contractor market:


New mobile jaw crusher generation
from Kleemann

At this years bauma Kleemann will show for the first time its new
jaw crushers Mobicat MC 110 Z and MC 110 R, which further expand the
successful EVO Contractor Line of Kleemann. Also here EVO represents a
redevelopment of the entire plants, real progress in terms of power and
efficiency.

Complete new designs


The plants of the new Mobicat EVO series have been
redesigned from scratch, thus allowing the combination of
new features such as the hopper walls integrated in the
chassis or a fully hydraulic crushing gap adjustment with
tried-and-tested concepts like the independent doubledecker pre screen, making the plants even more diverse
and efficient.

Issue 01 | 2013

Crusher direct drive, electric auxiliary


drives
Similar to the mobile impact crushers in the Mobirex
EVO series, drive variants with direct drive crushers and
electric drives for the vibrating conveyors, belts and the
pre screen, are now used for the mobile jaw crushers. This
means extremely efficient operation and allows optimal
loading of the crusher. The so-called CFS (Continuous
Feed System) controls an even more equal loading of the
crushing area, in which the conveying frequencies of the

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NEWS & REPORTS


feeder trough and the pre screen are adapted independently
of each other to the level of the crusher and thus help increase
the performance significantly.

New crushing unit with hoisted crusher


jaw
The new crusher impresses with its hoisted articulated
crusher jaw, which on the one hand prevents blocking of
coarse material and on the other hand takes all fastening
elements of the crusher jaw from the wear area. In addition,
the transfer from the pre screen or the feeder trough is
designed so that the material can simply tilt into the crushing
jaw and convey an even material flow. With this property and
other features Kleemann achieves outputs of up to 300 tons
per hour.

FOR MORE INFORMATION AND CONTACT:


Kleemann GmbH
Mark Hezinger
Manfred-Wrner-Str. 160
73037 Gppingen | Germany
Tel.: +49 (0)71 61 - 20 62 09
Fax: +49 (0)71 61 - 20 61 00
eMail: mark.hezinger@kleemann.info
Internet: www.kleemann.info

The new mobile jaw crushers from


Kleemann: Mobicat MC 110 EVO..

Kleemann GmbH
Kleemann GmbH is a member company of the Wirtgen Group, an expanding and international group of
companies doing business in the construction equipment industry. This Group includes the four well-known
brands, Wirtgen, Vgele, Hamm and Kleemann, with their headquarters in Germany and local production
sites in Brazil, India and China. Worldwide customer support is provided by its 55 own sales and service
companies.

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Kleemann GmbH

Kleemann at bauma 2013:

The concentrated power of mineral


processing!

Mobile primary crusher with


hourly output of up to 600 tons.

Kleemann presents a highlight at this years bauma with the global


premire of the new generation of mobile jaw crushers in the Contractor
Line, the new Mobicat EVO series. But apart from this there is still a
considerable amount to see at Kleemann: With a total of five mobile
crusher plants on display, Kleemann clarifies how comprehensive the
spectrum of applications of the Kleemann product range is.

Competence in natural stone


The two representatives of the Kleemann
Quarry Line are designed especially for
tough use in the area of natural stone. The
Mobicat MC 125 Z mobile jaw crusher is a
very powerful primary crusher, which with a
crusher inlet opening of 1250 x 1000 mm and a
weight of approx. 130 tons performs its work
also in adverse conditions and processes up
to 600 tons per hour. The Mobicone MCO 11 S
mobile cone crusher is a secondary crusher
for the second or third crushing stage and
with its integrated triple-deck screening
unit and the closed material cycle enables
production of three defined final grains.

Issue 01 | 2013

Diverse, powerful, efficient:


Mobirex MR 130 ZS EVO.

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Mobile secondary crushing plant with cone crusher and
triple-deck screening unit to meet the highest requirements
for grain form and output rate.

Kleemann GmbH
Kleemann GmbH is a member company of the Wirtgen Group, an expanding and international group of companies doing business
in the construction equipment industry. This Group includes the four well-known brands, Wirtgen, Vgele, Hamm and Kleemann,
with their headquarters in Germany and local production sites in Brazil, India and China. Worldwide customer support is provided
by its 55 own sales and service companies.

Diverse, efficient and extremely powerful


The Mobirex MR 130 ZS EVO mobile impact crusher,
the star of the Kleemann stand at the last bauma, has
more than established itself since its launch in 2010 in the
Contractor market. The MR 130 and its sister model MR
110 have proven themselves both in natural stone and in
diverse recycling applications to the extent that they now
belong to the most powerful and efficient representatives
in their class. The two completely redeveloped mobile jaw
crushers MC 110 Z EVO and MC 110 R EVO which will be
added to the Contractor Line of Kleemann from May of
this year, also want to offer this evidence. Similar to the
impact crushers in the Mobirex EVO series no bolt was
left untouched here. With its crusher inlet widths of 1100
x 700 mm the plants are targeting the so-called 1100 class,
which is the largest individual segment in the market of
mobile crusher plants. With the new plants Kleemann has
provided the basis to also conquer further market shares in
this class and establish itself over the long term.

FOR MORE INFORMATION AND CONTACT:


Kleemann GmbH
Mark Hezinger
Manfred-Wrner-Str. 160
73037 Gppingen | Germany
Tel.: +49 (0)71 61 - 20 62 09
Fax: +49 (0)71 61 - 20 61 00
eMail: mark.hezinger@kleemann.info
Internet: www.kleemann.info

DThe new mobile jaw crushers from


Kleemann: Mobicat MC 110 EVO.

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Wirtgen GmbH

Wirtgen: rounds out new generation of


cold recyclers and soil stabilizers

Cold recycling and soil stabilization made easy. The new WR


generation offers even greater output, high cost-efficiency and
easy handling.

Maximum quality every time the WR 240 already delivered this level of
performance when it was introduced to the market in summer 2012 as the first
representative of the new-generation cold recyclers and soil stabilizers. With
the two, new WR 200 and WR 250 models, Wirtgen now rounds out this product
segment in time for bauma 2013.

New standards in cold recycling and soil


stabilization

A small compact machine (WR 200)


meets a powerhouse (WR 250)

With the worlds largest line of recyclers and soil


stabilizers, Wirtgen has the right solution for every
application. For example, the WR 240 is considered to be
an all-rounder for the heavy-duty stabilization of large
areas of non-cohesive soil, and for the conservative cold
recycling of damaged asphalt layers. A variety of new
features make it a pioneer in terms of performance and
cost-efficiency, and it has impressively demonstrated both
of these in practical use in recent months, as the exclusively
positive feedback from customers confirms. Despite its
higher productivity, the WR 240 consumes significantly
less fuel thanks to state-of-the-art engine management,
and therefore considerably reduces costs for contractors.
What is more, their machine operators praise the large,
modern cabin, the all-around view it affords, the machines
improved manoeuvrability, its optimized ergonomic design
and its intuitive operation.

Wirtgen is presenting the WR 200 at bauma 2013, a


smaller version of the WR 240. It boasts nearly identical
features for both cold recycling and soil stabilization.
It shows off all its capabilities in these applications,
specifically its maneuverability on small, tight construction
sites. Furthermore, it requires no special transport permits
and is therefore ideal for one-day jobs.

Issue 01 | 2013

The WR 250 is the most heavy-duty machine of the new


WR generation. This powerhouse is designed for stabilizing
heavy, swampy soils and comes into its own on recycling
and pulverization jobs, where it turns roadways up to 25
cm thick into homogenous granulate. What is new is the
option of also operating the milling drum from the cabin,
making it possible to flexibly activate a number of milling
drum speeds. The milling drum design tailored to the WR
250s high output helps to achieve outstanding mix quality
at a high feed rate.

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Outstanding! Wirtgen won the iF product design award in


the category Special Vehicles / Construction / Agriculture for
the WR 240, one of the most coveted international design prizes.
The award evaluates aspects such as degree of innovation,
environmental impact, functionality, ergonomics and product
safety.

iF product design award for the Wirtgen


WR 240
In addition to their innovative features, all three models
lastly win out with their ultra-modern design. The WR 240
even won an iF product design award in 2013, one of the
worlds foremost design prices.

FOR MORE INFORMATION AND CONTACT:


Wirtgen GmbH - Press and Public Relations
Michaela Adams, Mario Linnemann
Reinhard-Wirtgen-Strae 2
53578 Windhagen | Germany
Tel.: +49 (0)26 45 - 1 31-0
Fax: +49 (0)26 45 - 1 31 499
eMail: presse@wirtgen.com
Internet: www.wirtgen.com

Cold recycling and soil stabilization made


easy. The new WR generation offers even greater
output, high cost-efficiency and easy handling.

Issue 01 | 2013

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NEUHEITEN & REPORTAGEN

ADVERTISEMENT
Ausgabe 01 | 2013

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Wirtgen Group

Two brands one solution: the Wirtgen Group


offers machines for the mining and processing of
minerals Wirtgen surface miners and Kleemann
crushers and screens.

Wirtgen Group Mineral Technologies:


Maximum reliability and economic efficiency

With the Wirtgen surface miners and Kleemann crushers and screens, the Wirtgen
Groups Mineral Technologies division offers a well-matched product range for
mining and processing minerals.
Extracting minerals from open-cast deposits and
processing mineral raw materials impose high demands on
man and machine. Durable, high-performance equipment
is essential here. The experiences gained in practical
applications are continually channelled into further
technological advancements and it is this which now
permits the Wirtgen Group to offer its customers technically
perfected, practical products which are designed to
withstand the most extreme operating conditions. From
material extraction to material processing, these robust
machines stand for reliability and economic efficiency.

by a special cutting drum before being transferred into


dumpers via sturdy conveyor systems all in a single pass.
Alternatively, the rock can be placed alongside the machine
or laid in windrows between the tracks. Only Wirtgen can
offer both of these options. As a result, surface miners are
very flexible to use. They have cutting widths of 2.20 to 4.20
m and cut down to depths of 20 to 83 cm at a uniaxial
compressive strength of up to 120 MPa. Special machines
for rock construction can even cut hard granite up to 260
MPa. Wirtgen is the only manufacturer which can offer a
performance range of 100 to 3,000 t/h.

Wirtgen surface miner


The well-established mechanical mining procedure
requires no drilling, blasting and pre-crushing. Instead,
the rock is first cut and crushed in the surface miner

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The product range: Individually
configurable standard machines
Wirtgen offers three time-proven performance classes
which can be configured variably to meet the needs of each
project: the 2200 SM, the 2500 SM and the 4200 SM. Over
two dozen cutting drum designs are available as standard
and further designs can be developed and built for specific
applications.
Used in open-cast mining, road routing work, railway
lines and tunnels, over 420 Wirtgen surface miners are
currently in operation around the world. The machines
can selectively extract valuable minerals, coal, limestone,
gypsum, bauxite, phosphate or iron ore with a high
degree of purity. Thanks to the continual expansion of the
machines range of applications, they can also be used for
special applications in salt, granite, kimberlite or oil shale
mining.

Surface mining sets standards Also in


terms of economy
A pioneer of surface mining technology, Wirtgen
GmbH has been developing the mechanical process
since the 1980s and has established it as an alternative
to conventional mining methods. Requiring no blasting,
the process avoids ground vibrations, noise and dust,
minimizing the environmental impact. Surface mining also
increases safety in the mines.

Mining companies who opt for surface mining make


immense cost savings, as the initial investment is not
only considerably lower than for conventional methods
the production costs are reduced by up to 40 percent,
too. What is more, they can also rely on Wirtgens longstanding application experience. For instance, the mining
experts are available to provide advice on site for the entire
duration of a project extending from the organization
of the project logistics to service in the mine. After all,
machine availability is crucial to success in the mining
business, where machines are in operation 24/7.
Local service bases and comprehensive services
offer customers maximum reliability when planning the
deployment of their machine fleets.

Kleemann crushers and screens


The Wirtgen Group offers a wide range of jaw, impact
and cone crushers as well as screens for processing
mineral raw materials and recycling construction materials.
Kleemann has been in the business of processing natural
rock and recycling materials for over 150 years. Recycling
materials and the chunks of rock obtained from drilling and
blasting work in quarries are processed into defined grain
sizes. These classified final granulations are used in road
and building construction, being standard additives for
concrete as well as for asphalt base, binder and surface
courses.

One of the key features of the Wirtgen surface miner is its ability to load
cut material directly onto trucks like this 4200 SM. The height-adjustable
conveyor can be swung 90 degrees to either side.

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In addition, Kleemann products are designed to tackle
hard minerals and materials in the mining sector. Kleemann
provides application consulting for its customers to help
them select the right machine for their requirements. This
ensures that products can be mined as economically as
possible at the specified daily rate.

The product range: Stand-alone


machines or interlinked machine
combinations
Jaw crushers in the MOBICAT line are the classic
primary crushers for natural rock. The performance range
of these mobile machines extends from 100 to 1,500 t/h.
Extremely robust, high-performance machines with feed
capacities of 450 to 1,000 t/h are used for traditional quarry
applications.
Secondary crushers such as track-mounted impact
crushers in the MOBIREX line and cone crushers in the
MOBICONE line are electrically connected to work in
tandem with primary crushers and screens. The screen
area of the chain-mounted screening plants ranges from 7
to 18.4 m. Their performance extends up to 1,000 t/h, making
them ideal for heavy duty operation and material which is
difficult to screen. Stationary plants with capacities of 100
to 1,000 t/h perform all the other individual tasks required
apart from crushing and screening i.e. washing, sand
processing, mixing, dust collection etc., rounding off the
product range.

Two brands One solution


The Wirtgen Group offers extremely robust, state-of-theart special machines in the field of mineral technologies:
namely Wirtgen surface miners and Kleemann crushers
and screens. With a wide range of products and decades
of practical experience in applications technology, the
Wirtgen Group offers its customers one-stop tailored
solutions, worldwide. Committed to advancing its machines
in collaboration with its customers and to providing an
optimum after-sales service extending from advice and
financing support to an on-site machine service the
Wirtgen Group is the ideal partner in the field of mineral
technologies.

FOR MORE INFORMATION AND CONTACT:


Wirtgen Group - Press and Public Relations
Michaela Adams, Mario Linnemann
Reinhard-Wirtgen-Strae 2
53578 Windhagen | Germany
Tel.: +49 (0)26 45 - 1 31-0
Fax: +49 (0)26 45 - 1 31 499
eMail: presse@wirtgen.com
Internet: www.wirtgen.com

Three MCO 13 S mobile secondary crushers for the


production of iron ore in a grain size of 0-10 mm.

Issue 01 | 2013

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Wirtgen Group

Wirtgen Group introduces 29 new


products at bauma 2013: Innovative

Solutions for Road and Mineral Technologies

Four strong brands, 91 innovative exhibits, 29 of which are pioneering world


premieres, 10,560 m of exhibition space and over 100 experienced specialists: these
impressive figures describe the Wirtgen Group at bauma 2013 and demonstrate its
innovative force in the Road and Mineral Technologies business segments.

Wirtgen Group sets the pace in the


industry
With their advanced solutions, the strong Wirtgen,
Vgele, Hamm and Kleemann brands are once again
setting the pace in the industry. Tailored closely to needs in
the field, the new Wirtgen Group machines offer customers
added value that greatly facilitates their everyday work at
the construction site, mine or quarry.
With six world premieres, Wirtgen is ringing in a new
era in roadway construction. Be it new construction or
rehabilitation, road building companies are ideally equipped
to meet any challenge with the two, new-generation cold
recyclers and soil stabilizers as well as slipform pavers.
Maximum process reliability, lower fuel consumption,
greater ease of operation: that is the new dash 3
generation from Vgele. Eleven world premieres among
the road pavers and extending screeds can be seen live
at bauma 2013.
With world premieres in the H, HD+ and HD CompactLine
product families, Hamm rounds out its range of high-quality
vibratory compactors and tandem rollers. Efficiency is the
keyword for the future of compaction technology.

Issue 01 | 2013

The new MOBICAT EVO line of mobile jaw crushers


sets new standards in the contractor market. The three
world premieres from Kleemann boast high efficiency and
versatility.

EExperience the Wirtgen Group stand at


the trade show: New perspectives for
visitors
In line with its theme Innovative Solutions for Road and
Mineral Technologies the Wirtgen Group is showing not
only world premieres, but also an impressive cross-section
of its full-service portfolio. The dimensions of Wirtgen
Groups trade show stand are equally as impressive. The
total area has increased considerably since bauma 2010;
in fact the Wirtgen Group has the third-largest exhibition
space at bauma 2013. As if that were not enough, the
stand has even grown vertically: visitors can discover
the Wirtgen Group world on two levels for the first time in
2013. While the hardware is on display on the ground floor
in the product area and technology pavilions, customers
can experience the Wirtgen Groups other services on the
second floor. From applications consulting and financial

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solutions to after-sales service, visitors learn here how


the Wirtgen Group lives up to its pledge close to our
customers every day.

Wirtgen Group experts in Munich


Experts for the Wirtgen, Vgele, Hamm and Kleemann
brands, and from the 55 sales and service organizations
worldwide, will be on hand at bauma 2013 to answer any
questions surrounding road and mineral technologies.

Issue 01 | 2013

For more information on Wirtgen Group at


bauma 2013, go to:
www.wirtgen-group.com/bauma
FOR MORE INFORMATION AND CONTACT:
Wirtgen Group - Press and Public Relations
Michaela Adams, Mario Linnemann
Reinhard-Wirtgen-Strae 2
53578 Windhagen | Germany
Tel.: +49 (0)26 45 - 1 31-0
Fax: +49 (0)26 45 - 1 31 499
eMail: presse@wirtgen.com
Internet: www.wirtgen.com

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Continuous training for the


Mining industry:
Advanced Mining Academy
More information about the

ADVANCED MINING ACADEMY


you will find here:

www.advanced-mining.com/academy

ADVERTISEMENT

Issue 01 | 2013

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Bell Equipment (Deutschland) GmbH

Bell celebrates:

The European Bell factory in Eisenach, Germany, is


gearing up for the new E-series models.

10 years of German manufacturing


at BAUMA 2013!

2013 will be a milestone year in the history of Bell Equipments German manufacturing facility,
which celebrates its 10-year anniversary and gears up for the production of the new Bell E-series
generation of Articulated Dump Trucks (ADTs) later in the year. Following the companys recent
announcement to re-enter the Americas, the worlds largest ADT market, the factory will also
increase its production to supply Bell ADTs to this strategic new market.

10 years of German
manufacturing
Comments Bell Equipment Group Chief
Executive, Gary Bell: Having started
manufacturing in Germany 10 years ago weve
had a fair opportunity to assess the value of
producing our trucks in Europe and going forward
we believe that our decision to produce in
Germany is still good and valid. Weve positioned
the company well to leverage new opportunities
and are looking forward to the exciting times that
lie ahead. We are also satisfied with the quality
of our product from this factory; its produced
to a high standard as expected from a German
facility.

The European Bell factory in Eisenach, Germany, is gearing


up for the new E-series models. (Photos: Bell Equipment)

The flow-line concept with parallel component preparation of Bell Equipments


European ADT factory allows the flexible production of all models according to market
demand. Bell Eisenach assembles all Blu@dvantage Bell trucks for the companys
EU-IIIb markets and North American Tier4i markets. (Photos: Bell Equipment)

Looking back Bell Equipment started


construction on its German manufacturing facility
at Eisenach at the beginning of 2003 and the first
of its European-produced D-series Articulated
Dump Trucks (ADTs) rolled of the production line
in October that same year. Ten years later Bell
Equipment has established itself as a strong,
reliable ADT specialist in the construction
industry and earthmoving sector. In addition the
company has grown its local supplier database,
showing its deep-rooted commitment to the
European region.

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Highly qualified personnel form the backbone of Bell Equipments


assembly concept in Eisenach, Germany. Here driveline components
such as Mercedes-Benz engines and Allison transmissions are prepared
in parallel to the truck assembly. (Photos: Bell Equipment)

The company took the decision to develop the German


factory following the immense worldwide success of
its D-series ADT. Recalls Bell: ADT production at our
South African factory was near capacity and developing
a European assembly plant presented many benefits in
terms of flexible production, short delivery distances,
improved logistics, the guarantee of additional machines
and the strategic positioning for future growth in Central
and Eastern Europe.
During the initial phase the factory supplied product to
North America, however, that was terminated in 2005 due
to a new arrangement with our American partners. Prior to
this the factory had reached its design volumes and was
running with pleasing efficiency, he said.
While volumes have not been as great as expected
in recent years, and the European market hasnt fully
recovered from the 2008/2009 global recession, it has
provided sufficient volume for the factory and given us the
benefit of not having to round trip our product. This has
enabled us to focus on localising some of our component
manufacture to Germany as well as to build our markets
in the region and grow our distribution footprint to provide
better support.

The European factory was designed from the outset to assemble


the varied Bell truck range from the smaller trucks up to the flagship
Bell B50D. After strict end-of-line checks the Bell trucks are delivered
to Bell dealers and customers across the northern hemisphere.
(Photos: Bell Equipment)

as the Canadian dealer and distributor of its range of ADTs.


Said Bell: We are excited to be able to return to these
markets, ADTs are the backbone of our business and a
product we specialise in and access to the American
markets is key to our global plans. As such we have planned
for a significant increase for North American volumes off
a low base.
Meanwhile work to equip and convert the German
factory for the manufacture of the full range of E-series
ADTs started early in 2013. The E-series meets the next
tier of engine emission requirements and features some
of the most cutting edge ADT technology to build on the
companys heritage as an ADT specialist.
Concludes Bell: 2013 should be a exciting year for the
company in terms of growing our presence in North and
South America and launching our E-series ADT to the
global market. At the factory research and development
continues strongly and this year we begin testing our 60ton truck.
Gary Bell, Bell Equipment Group CEO.
(Photos: Bell Equipment)

As volumes increase to Eastern Europe, in particular


Russia, it is our intent to further improve local value add
and improve the companys competitiveness in these
markets, he added.
Although the overall market outlook for 2013 is not
positive, with a 5 to 10% drop in market sales forecast, Bell
is hoping to maintain similar levels to 2012 and has planned
for a 15% increase in European volumes. In addition the
facility will re-launch the production of trucks for the North
Americas following the appointment of Wajax Equipment

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Bell Equipment (Deutschland) GmbH

International market introduction:

E-Series takes ADTs into new era!

Bell Equipments new E-series, represented at BAUMA 2013 by the B30E, is set to build on the companys strong heritage as an Articulated
Dump Truck specialist. The new range offers latest developments in 6x6-technology, continuing to provide class leading power and weightratios, advanced engine and drivetrain characteristics. (Photos: Bell Equipment)

Previewed at last years Intermat show, the brand-new Bell B30E will take centre stage for
Bell Equipment at BAUMA 2013 to start the market introduction of Bell Equipments evolutionary
new E-Series ADT range (Hall B4, Stand 108). Following the modular performance class concept
Bell launches its new 30-tonner together with the smaller Bell B25E, both incorporating latest
developments in 6x6-technology. While continuing to provide class leading power and weightratios, advanced engine and drivetrain characteristics, both models set new standards in safety,
driver comfort and truck management.
The Bell B30E, on display at BAUMA 2013, showcases
the improvements Bell Equipments design engineers have
made in the key areas of performance and fuel efficiency.
They have also taken ADT functionality to new levels
with customer-focused advancements and the highest
level of automated machine protection. The all-new truck
platform has been specifically engineered to handle future
emissions requirements and take ADT innovation into the
next era.

Issue 01 | 2013

Defining new standards on proven


grounds
Fuel burn can contribute more than 40% of the operating
cost on a site and has, therefore, always been a major
focus area for Bell Equipment, especially in reacting to
international emission restrictions schemes. The latest
generations of Bell D-series trucks introduced their Blu@
dvantage SCR-technology (Selective Catalytic Reduction
) as an industry leading standard in fuel-efficient emission

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Bell Equipments new E-series, represented at BAUMA 2013 by the B30E, is set to build on the companys strong heritage as an Articulated
Dump Truck specialist. The new range offers latest developments in 6x6-technology, continuing to provide class leading power and weightratios, advanced engine and drivetrain characteristics. (Photos: Bell Equipment)

control, compliant to Tier4i and EU-IIIB. Whilst the


E-series platform has been designed for upcoming legal
requirements, first generations of the new B25E (210 kW/1
120 Nm) and B30E (240 kW/1 300 Nm) continue to use
the proven Blu@dvantage engine configurations of their
predecessors, but engine power and fuel consumption
have been additionally optimized through event dependant
software that controls retardation, cooling and charging of
accumulators.
Bell Equipments D-series platform, particularly for
its larger ADTs, has continuously emerged as the best in
class during its long lifetime due largely to the companys

evolutionary approach to design. It should come as no


surprise that Bell Equipment engineers have opted to
carry this platform through to the smaller trucks in the
new E-series range by changing the front suspension on
the smaller E-series trucks to an A-frame layout. Weve
increased the suspension travel and the A-frame gives
a more independent ride. In ride quality evaluations
numerous operators have been unanimous in their approval
and appreciation of the improvements achieved on the
E-series, commented Tristan du Pisanie, Bell Equipments
B30E Project Manager. Additionally, wider tyres are offered
as an option on the B30E, while importantly still keeping
the machine width below 3m to allow for easy on-road
transportation of the truck to job sites in Europe.
In keeping with the practice of
carrying through attributes from the
larger Bell ADTs to the smaller trucks,
the company has switched to Allison
The Bell E-series sets new standards in
safety, driver comfort and truck management.
Taking the driver experience to a new level
is the Isringhausen seat with a three point
safety harness, designed to improve ride
comfort and reduce whole body vibration with
its own suspension and dampening system.
On the dashboard a full colour screen and
an automotive mouse interface has been
introduced to control the sealed display unit,
which features more detailed and user-friendly
onboard diagnostics. (Photos: Bell Equipment)

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NEWS & REPORTS

With the E-series Bell Equipments engineers have carried through the A-frame suspension used on
the larger ADT models to the smaller trucks in the range to increase suspension travel and deliver a more
independent ride. The result? An unparalleled experience in terms of ride quality. (Photos: Bell Equipment)

transmissions. Bell previously used Allison transmissions


on the small C-series trucks and believes that the change
offers improvement in performance due to greater
efficiency. Importantly the change is in alignment with Bell
Equipments single family design concept.

Therefore the E-series cab has a full colour screen and


an automotive mouse interface to control the sealed display
unit. The Bell ADT is the first to offer this technology and
the standard reversing camera can also been integrated
into the colour screen display.

For improved safety and productivity the E-series has


an automatically engaged Inter-axle Differential Lock (IDL)
giving the vehicle full automatic traction control. A sensor
on the inter-axle differential identifies when an axle loses
traction and automatically engages the IDL function while
the vehicle is still moving. This feature is working so well
that the diff lock button on the Sealed Switch Module (SSM)
may soon become redundant, says du Pisanie. In addition
the B30E and B25E ADTs both have limited slip differentials
in each axle so the cross locking of wheels is achieved
automatically without any interaction from the operator.

Bell opted for an Isringhausen seat, with its own


suspension and dampening system, to improve ride
comfort and reduce whole body vibration. The seat also
has a three point safety harness which can be configured,
as an additional safety feature, so that the trucks engine
will only start once the seat harness is fastened. Heated
seats are an option for colder climates.

Driver comfort = owner profit


According to Tristan du Pisanie, the operators experience
has been a key focus area and various improvements to the
cab and suspension performance have been made with
this in mind. We wanted to build on what we had achieved
with our long-standing successful D-series by simplifying
the interface and making the cab more ergonomic where
possible. When we looked at how to improve the operators
experience we took into consideration the lifestyles of
todays younger generation of operators. Smartphone
technology is growing in popularity and we also wanted to
build the familiarity of what happens in your car into what
happens in our E-series trucks, explains du Pisanie.

Issue 01 | 2013

Modern flowing lines, in keeping with the current styling


trend on road vehicles, offer the operator unsurpassed
levels of visibility while lights have been positioned higher
up on the body where they will be less inclined to attract
mud. Additionally all surface areas that could potentially
come into contact with hazards on the job site now
incorporate a rolled steel section for even higher durability.
Safety systems and features, such as handrails and high
visibility mirrors, have been styled into the project from
the beginning so that the finished product is aesthetically
pleasing and polished.

Advanced ADT Intelligence


A lot of thought and testing has gone into the E-series
design and the engineering team has had detailed
interactions with customers, operators and the Bell Sales
Team, says du Pisanie. As a result the onboard diagnostics

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NEWS & REPORTS


are more detailed and user friendly. The E-series truck can
store up to 72 hours of machine operation and there are
more proactive advance warnings for the hydraulic system.
Another technological advancement is that a Bell Field
Technician can plug the screen display onto his laptop and
link with our Engineering team in Richards Bay so that they
can see the screen display and see exactly what is going
on with a truck anywhere in the world.
In line with the improved diagnostics, Bell Equipments
satellite fleet monitoring system, Fleetm@tic is also
undergoing a major facelift with a new web application
focussing on mapping utility so that Fleetm@tic is available
on all multi-media including tablets, smartphones and PCs.
The geofencing feature is to be reconfigured to increase
vehicle safety by facilitating geofencing in multiple zones
based on speed limitations related to load, inclination and
site conditions. An additional feature will be a map tracking
utility giving per minute tracking data.
Of course Bell Equipments other ground-breaking
innovations such as keyless ignition, HillAssist, Bin Tip
Prevention, Auto Park Application (APA), standard Turbo
Spin Protection and On-Board Weighing (OBW) are
still standard on the E-series. OBW-Accuracy has been
improved through the addition of an additional load cell to
compensate for different loading styles.

Proven and tested concept


Bell Equipments Head of Engineering, Pieter Goosen
says that the E-series has been in development for the
past five years and has undergone stringent durability
testing, having enlisted reputable independent national
and international test facilities for additional verification.
Development has followed a well-structured process
that has included an unprecedented level of customer
interaction, concept vehicles and numerous prototypes
to ensure a strong, reliable product. Extensive testing
formed part of the process and engineers used structural
analysis and dynamic analysis along with a rigorous
testing programme on some of the harshest mine sites in
the world to ensure that the E-series is worthy of taking the
Bell marque forward.
We are confident that with Bell Equipments continuous
development philosophy the E-series platform will take us
well into the next decade to further strengthen our pedigree
as the ADT specialist, he said.

Table:
Key technical data B25E and B30E (* Weights are best estimates based on
measurements done on pre-production trucks and exclude bin liners and tailgate)

Engine
Gross power
Gross torque
Bin volume (SAE 2:1)
Unladen weight*
Payload

B25E

B30E

OM926LA, Stage 3B
210 kW @ 2 200 rpm
1120 Nm @ 1200 - 1600 rpm
15,0 m
19 000 kg
24 000 kg

OM926LA, Stage 3B
240 kW @ 2 200 rpm
1300 Nm @ 1200 -1600 rpm
17,5 m
19 950 kg
28 000 kg

FOR MORE INFORMATION AND CONTACT:


Bell Equipment U.K.
Unit 6 C, Graycar Business park,
Barton-Under-Needwood,
Burton-on-Trent
Bell Equipment International
DE13 8EN
United Kingdom
Stephen Jones, Manager Group Marketing
Bell Equipment Co. SA.
Phone: +44 (0) 1283 712862
Fax: +44 (0) 1283 712687
Tel.: +27 (0) 35 907 9431
eMail: general@bellequipment.co.uk
Fax: +27 (0) 35 797 4323
Internet: www.bellequipment.co.uk
eMail: stephenj@bell.co.za
Internet: www.bellequipment.com

Issue 01 | 2013

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Bell Equipment (Deutschland) GmbH
The newest addition to the Bell
VersaTruck range, the B30D 4x4 will
be on show at BAUMA 2013. The 4X4
base offers improved manoeuvrability,
with tighter turning circle and shorter
dimensions without impacting on payload and engine performance. A cost
effective, tailor made OEM solution for
customers not requiring the functionality of a standard 6x6 ADT but still
needing the higher flexibility offered
by an articulated truck in terms of
terrain and weather capabilities with
reduced operating cost. (Photos: Bell
Equipment)

BEll
VersaTruck:

Full OEM solutions for niche markets


Bell Equipments ability to listen to the needs of its customers and successfully translate
these needs into tailor made machine solutions has led to the introduction of a new product
to the companys VersaTruck programme, namely a B30D 4x4 to be displayed on the Bell
BAUMA stand (Hall B4, Stand 108).
The company, which was built on the specialised
machinery concept, is recognised as the Articulated
Dump Truck specialist and takes versatility to a
whole different level with its VersaTruck programme.
Customers are able to choose from a number of Bell ADT
permutations to best suit their application requirements.
Included in Bell Equipments extensive list of tailor made
solutions are ejector trucks, fire trucks, water tankers,
lube trucks, flat deck trucks, hooklift trucks, container
trucks, concrete trucks, timber trucks, waste handlers,
waste compactors and even an underground concrete
mixer.
Managing this programme is the Bell Application
Equipment (BAE) division, a substantial team with
years of experience, which is dedicated to the design,
fabrication and assembly of the Bell niche products.
Clinton Wissekerke heads up this team and tells us
about the latest addition to the programme.
The B30D 4x4 solution for earthmoving and quarrying
applications, which will be on display at BAUMA 2013,
has arisen from specific enquiries from the industry.
Wissekerke said: Over the past few years weve
worked on several 4x4 variations on our D-series
platform including the B15D for light duty industrial

Issue 01 | 2013

applications, the T302D Timber Haulers and now the


B30D 4x4, which is particularly well suited for use in
quarrying applications worldwide.
Wissekerke explains the reason for the 4x4 ADT:
Providing the same payload and engine performance
as our standard B30D, the 4x4 option offers a tighter
turning circle and shorter dimensions compared
to our traditional 6x6 ADT with their optimized offroad capability. It therefore suits customers needing
improved manoeuvrability, but still needing the higher
flexibility (weather independence, heavy terrain) of an
articulated truck compared to rigid chassis alternatives
on the market. These customers may also reduce tyre
costs - a major portion of the operating cost of an ADT
- simply through reduced tyre scuffing associated with
the third axle.
Adds Bell Equipments Marketing Manager: ADTs,
Llewellyn Roux: Of course the VersaTrucks are able to
offer the best in performance, safety, fuel efficiency and
ease of operation of our standard ADT range. Similarly
they also have all the latest innovations and features,
among them onboard weighing, keyless ignition,
HillAssist, Bin Tip Prevention, Auto Park Application
(APA), standard Turbo Spin Protection and our satellite
fleet management system Fleetm@tic.

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By offering complete OEM solutions to our niche


markets we are able to provide an OEM warranty
knowing that these machines are built according to
our uncompromising design philosophy and quality
standards. Importantly this also means that a Bell
Versa Truck solution is guaranteed of Bell Equipments
technical support offered through our comprehensive
global network of customer service centres and
dealers, he says.

The VersaTruck programme has been borne from Bell Equipments


ability to listen to the needs of its customers and successfully translate
these needs into tailor made machine solutions. These complete OEM
solutions - including ejector trucks, water tankers, hooklift trucks and
ADTs with fifth wheels - come with an OEM warranty knowing that these
machines are built according to Bell Equipments uncompromising design
philosophy and quality standards. (Photos: Bell Equipment)

Key technical data B30D 4x4

Gross power

240 kW

Gross torque

1 250 Nm

Bin volume (SAE 2:1)

17,0 m

Unladen weight

17 250 kg

Payload

27 000 kg

FOR MORE INFORMATION AND CONTACT:


Bell Equipment International
Bell Equipment U.K.
Stephen Jones,
Manager Group Marketing
Unit 6 C, Graycar Business park,
Bell Equipment Co. SA.
Barton-Under-Needwood,
Burton-on-Trent
Tel.: +27 (0) 35 907 9431
DE13 8EN
Fax: +27 (0) 35 797 4323
United Kingdom
eMail: stephenj@bell.co.za
Phone: +44 (0) 1283 712862
Internet: www.bellequipment.com
Fax: +44 (0) 1283 712687
eMail: general@bellequipment.co.uk
Internet: www.bellequipment.co.uk

Issue 01 | 2013

The newest addition to the Bell VersaTruck range, the B30D 4x4 will be
on show at BAUMA 2013. The 4X4 base offers improved manoeuvrability,
with tighter turning circle and shorter dimensions without impacting on
payload and engine performance. A cost effective, tailor made OEM
solution for customers not requiring the functionality of a standard 6x6
ADT but still needing the higher flexibility offered by an articulated truck in
terms of terrain and weather capabilities with reduced operating cost.

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Komatsu Europe International N.V

HD785-7 Rigid Dump Truck


Performance and Safety

omatsus 91-tonne capacity rigid dump truck will be on display at Bauma 2013. The HD785-7 offers
K
impressive engine power and brake retardation, as well as excellent fuel efficiency. Its powerful and
efficient Komatsu SAA12V140E-3 engine delivers 1178 HP at 1900 rpm and provides great acceleration,
low fuel consumption with a top speed of 65 km/h.

To optimise performance and fuel consumption, the


engine is fitted with a variable horsepower control
(VHPC). This system sets the maximum engine power
to one of four levels to match the job being carried out
and the working conditions. The operator chooses
between power and economy mode, and the VHPC
automatically detects whether the machine is loaded
or unloaded. Consequently, the HD785-7 delivers
excellent climbing ability when required and fuel
consumption can be reduced.
The HD785-7 has an advanced transmission
that effectively harnesses the engine power, with
7 forward and 2 reverse gears. The transmission
includes K-ATOMiCS, Komatsus electronically
controlled clutch modulation system, which controls
both the engine and transmission to optimise clutch
engagement. Combined with a skipshift function
that automatically matches the travel speed to the
incline, this system ensures smooth gear shifting and
responsive acceleration.

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A number of other features improve operational safety,


such as the advanced retarder braking system. With a
capacity of 1464 HP for continuous decent, the largest
in its class and more than the engine power, this system
ensures the safest downhill travel. It includes Komatsus
anti-pitching 4-wheel oil-cooled multiple disc retarder,
which shares the retarding force between all four wheels
to reduce tyre-lock and allow smooth downhill travel. In
addition, the auto-retard speed control (ARSC) allows preselecting a constant downhill speed so the operator can
concentrate on steering.

For even greater safety, the HD785-7 can optionally


be fitted with an anti-lock braking system (ABS), and an
automatic spin regulator (ASR) that prevents the rear
tyres from slipping on soft ground, improving traction and
braking. With a heaped capacity of 60 m3, the HD785-7 is
matched to Komatsus PC1250 and PC2000 excavators, and
WA800 and WA900 wheel loaders.

FOR MORE INFORMATION AND CONTACT:


Komatsu Europe International N.V.
Kevin Broman
Corporate Branding Coordinator
Tel.: +32 2 255 24 58
eMail: kevin.broman@komatsu.eu
Komatsu Europe
Bettina Meeuw
Komatsu Sales Promotion Coordinator
Hanomagstrae 9
30449 Hanover
Tel.: +49(0) 511 4509 212
eMail: bettina.meeuw@komatsu.eu
Internet: www.komatsu.eu
www.komatsu-deutschland.de

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Komatsu Europe International N.V

New Komatsu WA380-7 Wheel Loader

Powered by EU Stage IIIB/EPA Tier 4 interim Engine Technology.


With Komatsu CARE A complimentary maintenance program
for customers.
The new WA380-7 wheel loader will be
displayed at Bauma 2013

friendly engine that increases power while lowering fuel


consumption by approximately 10 per cent, compared
to the WA380-6.

BWeighing in at 17,910 kg, the WA380-7 features


improved efficiency, lower fuel consumption, improved
operator comfort, and enhanced serviceability to
maximize productivity while reducing operating costs.

The WA380-7 is supported by Komatsu CARE, a


complimentary maintenance program for Komatsu
customers that comes as standard with every new
Komatsu S3B construction machine. For the first
three years or 2.000 hours it covers factory-scheduled
maintenance,
performed
by
Komatsutrained
technicians with Komatsu Genuine parts. Komatsu CARE
offers up to a maximum of 2 complimentary Komatsu
Diesel Particulate Filter (KDPF) exchanges and a KDPF
warranty for the first 5 years or 9.000 hours.

With a net horsepower of 191 hp (143 kW), the


WA380-7 is powered by a Komatsu SAA6D107E-2
engine and is EU Stage IIIB/ EPA Tier 4 Interim emission
certified (S3B). Built upon a proven Stage IIIA engine
platform, Komatsu has leveraged its leadership in
technology and innovation to design an environmentally

Issue 01 | 2013

The latest KOMTRAX technology on the WA380-7


sends machine operating information to a secure
website utilizing wireless technology. Data such as
operating hours, fuel consumption, location, cautions
and maintenance alerts are relayed to the web
application for analysis. New data includes details
about the type of work the machine is doing and a
performance report of Komatsus new EU stage IIIB
engine and its Komatsu Diesel Particle Filter (KDPF).
KOMTRAX communicates the number of active KDPF
regenerations performed by the machine, and the time
spent doing them.

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The KOMTRAX fleet monitoring system increases
machine availability, reduces the risk of machine theft,
allows for remote diagnosis by the distributor, and
provides a wealth of other information to drive business
efficiency and productivity.

New features of the WA380-7 include:


EU Stage IIIB/EPA Tier 4 interim Emission
Certified Engine
Built upon proven Stage IIIA technology, the
SAA6D107-E2 engine provides lower emissions while
also lowering fuel consumption. The Komatsu S3B
engine uses an advanced electronic control system
to manage air flow rate, fuel injection, combustion
parameters and after-treatment functions to optimize
performance, reduce emissions and fuel consumption,
and provide advanced diagnostic capability.
As a leader in hydraulic technology, Komatsu has
also developed a hydraulically actuated Komatsu
Variable Geometry Turbocharger (KVGT) and an
Exhaust Gas Recirculation (EGR) valve, resulting in
better precision and air management as well as longer
component life. The Komatsu Diesel Particulate Filter
(KDPF) has an integrated design that will not interfere
with daily operation but will keep the operator aware of
its status.

Issue 01 | 2013

The WA380-7 also features Komatsu SmartLoader


Logic, which provides optimal engine torque for the job
required. Komatsu SmartLoader Logic helps to save fuel
by automatically decreasing engine torque when the
loader isnt working hard, such as when it is driving with
an empty bucket. Komatsu SmartLoader Logic functions
automatically and doesnt interfere with operation,
saving fuel without decreasing production.

Large Capacity Torque Converter with Lock-Up


The WA380-7 has a newly designed Komatsu Large
Capacity Torque Converter with Lock-Up as a standard
feature. This provides improved acceleration and
hill climb ability, a higher top speed and lower fuel
consumption. The Lock-Up function activates in 2nd, 3rd
and 4th gears and gives the machine a maximum ground
speed of 40 km/h.
The wheel loader has greater productivity in V-cycle
applications because of the increased tractive effort.
The improved hill climbing ability allows the WA380-7 to
upshift gears faster because of better acceleration. The
Komatsu WA380-7 can also achieve higher gear ranges
and maintain higher ground speeds when working
in load-and-carry applications. In most applications,
production is increased and fuel consumption reduced,
resulting in improved fuel efficiency.

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Enhanced Operator
Environment
The new cab provides a
comfortable work environment
with a reduced interior sound
level of only 68 dB(A) so operators
can maximize their productivity.
The front glass was lowered and
the dashboard redesigned to
improve visibility. The short lever
Electronic Pilot Control (EPC) is
connected directly to the operator
seat. A precise and comfortable
temperature can be set with the
Climate Control system, and a CDRadio including two 12Volt ports
was incorporated into the cab.
A new high resolution 7 LCD monitor features
enhanced capabilities and displays information in 25
languages, for global support. Using the monitor, the
operator can easily modify settings for items such as the
auto idle shutdown or the auto-reversing fan. Operators
can also check operational records, such as working
hours or fuel consumption; monitor the KDPF; or check
how much time is required before the next maintenance
interval. The monitor offers the option of using the ECO
Guidance function, which provides operational tips to
reduce fuel consumption. A separate high-resolution
back-up camera is standard with every machine and
is mounted on the right hand side of the console for
operator convenience.

Convenient Maintenance and Serviceability


The WA380-7 provides easy service access to reduce
costly downtime. The new model has increased cooling
capacity, wider cooling fin spacing and a standard
auto-reversing fan to help keep the radiator clean. The
machine is equipped with the exclusive Komatsu EMMS
(Equipment Management Monitoring System), which
has enhanced diagnostic features that give the operator
and technicians greater monitoring and troubleshooting
capabilities. EMMS also continuously monitors all
critical systems, preventative maintenance, and provides
troubleshooting assistance to minimize diagnosis and
repair time.

Greater versatility
An easy-to-clean radiator compartment in combination
with an auto reversible radiator fan effectively supports
work on job sites that are littered with a lot of debris.
A newly designed multi-function lever has integrated
proportional controls for the easy handling of attachments
that require a third hydraulic line, such as High-Dump
buckets. For attachments, you can adjust the flow rate
individually and select a continuous or proportional flow,
and the new unique user interface allows saving your
customized settings.

Issue 01 | 2013

Quick Specs
Operating weight

17,910kg

Engine power (ISO 14396)

143kW

Hinge pin height

4,095mm

Dumping Clearance ( with 3.2m bucket


with teeth)

2,915mm

Full turn static tipping load (at 37)

12,890kg

FOR MORE INFORMATION AND CONTACT:


Komatsu Europe
Komatsu Europe International N.V.
Bettina Meeuw Coordinator
Kevin Broman
Komatsu Sales Promotion
Corporate Branding Coordinator
Hanomagstrae 9
Tel.: +32 2 255 24 58
30449 Hanover
eMail: kevin.broman@komatsu.eu
Tel.: +49(0) 511 4509 212
eMail: bettina.meeuw@komatsu.eu
Internet: www.komatsu.eu
www.komatsu-deutschland.de

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Komatsu Europe International N.V

New Komatsu WA500-7 Wheel Loader

Powered by EU Stage IIIB/EPA Tier 4 interim Engine Technology.


With Komatsu CARE A complimentary maintenance program
for customers.
The new WA500-7 wheel loader will be
displayed at Bauma
2013. Weighing in at 33.335 kg, the WA500-7 features
improved efficiency, lower fuel consumption, improved
operator comfort, and enhanced serviceability to
maximize productivity while lowering operating costs.
With a net horsepower of 352 hp (263 kW), the
WA500-7 is powered by a Komatsu SAA6D140E-6 engine
and is EPA Tier 4 Interim and EU Stage IIIB emission
certified. Built upon a proven Stage IIIA engine platform,
Komatsu has leveraged its leadership in technology
and innovation to design an environmentally friendly
engine that increases power while decreasing fuel
consumption by approximately 10 per cent, compared to
the WA500-7.

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NEWS & REPORTS


The WA500-7 is supported by
Komatsu CARE, a complimentary
maintenance
program
for
Komatsu customers that comes
as standard with every new
Komatsu S3B construction
machine. For the first three
years or 2.000 hours it covers
factory-scheduled maintenance,
performed by Komatsutrained
technicians
with
Komatsu
Genuine parts. Komatsu CARE
offers up to a maximum of
2
complimentary
Komatsu
Diesel Particulate Filter (KDPF)
exchanges and a KDPF warranty
for the first 5 years or 9.000
hours.
The latest KOMTRAX technology on the WA500-7
sends machine operating information to a secure website
utilizing wireless technology. Data such as operating hours,
fuel consumption, location, cautions and maintenance
alerts are relayed to the web application for analysis. New
data includes details about the type of work the machine
is doing and a performance report of Komatsus new EU
stage IIIB engine and its Komatsu Diesel Particle Filter
(KDPF). KOMTRAX communicates the number of active
KDPF regenerations performed by the machine, and the
time spent doing them. The KOMTRAX fleet monitoring
system increases machine availability, reduces the risk
of machine theft, allows for remote diagnosis by the
distributor, and provides a wealth of other information to
drive business efficiency and productivity.

New features of the WA500-7 include:


EU Stage IIIB/EPA Tier 4 interim Emission
Certified Engine
Built upon proven Stage IIIA technology, the
SAA6D140E-6 engine provides lower emissions while also
lowering fuel consumption. The Komatsu EU Stage IIIB/EPA
Tier 4 interim engine uses an advanced electronic control
system to manage air flow rate, fuel injection, combustion
parameters and after-treatment functions to optimize
performance, reduce emissions, reduce fuel consumption
and provide advanced diagnostic capability.

Recirculation (EGR) valve, resulting in better precision


and air management as well as longer component life. The
Komatsu Diesel Particulate Filter (KDPF) has an integrated
design that will not interfere with daily operation but will
keep the operator aware of its status.
The WA500-7 also features Komatsu SmartLoader
Logic, which provides optimal engine torque for the job
required. Komatsu SmartLoader Logic helps to save fuel
by automatically decreasing engine torque when the
loader isnt working hard, such as when it is driving with
an empty bucket. Komatsu SmartLoader Logic functions
automatically and doesnt interfere with operation, saving
fuel without decreasing production.

Large Capacity Torque Converter with Lock-Up


The WA500-7 has a newly designed Komatsu Large
Capacity Torque Converter with Lock-Up as a standard
feature. This provides improved acceleration, improved
hill climb ability, a higher top speed and lower fuel
consumption. The Lock-Up function activates in 2nd, 3rd
and 4th gears and gives the machine a maximum ground
speed of 40 km/h.
The wheel loader has greater productivity in V-cycle
applications because of the increased tractive effort.
The improved hill climbing ability allows the WA500-7 to
upshift gears faster because of improved acceleration.
The wheel loader can also achieve higher gear ranges
and maintain higher ground speeds when working in loadand-carry applications. In most applications, production
is increased and fuel consumption reduced, resulting in
improved fuel efficiency.

As a leader in hydraulic technology, Komatsu has also


developed a hydraulically actuated Komatsu Variable
Geometry Turbocharger (KVGT) and an Exhaust Gas

Issue 01 | 2013

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NEWS & REPORTS


Enhanced Operator Environment
The new cab provides a comfortable and quiet work
environment so operators can maximize their productivity.
The front glass has been lowered and the dashboard has
been redesigned to improve visibility. The short lever
Electronic Pilot Control (EPC) is connected directly to the
operator seat. A precise and comfortable temperature can
be set with the Climate Control system, and a CD-Radio
including two 12Volt ports was incorporated into the cab.
A new high resolution 7 LCD monitor features enhanced
capabilities and displays information in 25 languages
for global support. Using the monitor, the operator can
easily modify settings for items such as the Auto Idle
Shutdown or the auto-reversing fan. Operators can also
check operational records, such as working hours or
fuel consumption; monitor the KDPF; or check how much
time is required before the next maintenance interval. The
monitor also offers the operator the option of using the
ECO Guidance function, which will provide operational tips
to reduce fuel consumption. A separate high-resolution
back-up camera is standard with every machine and is
mounted on the right hand side of the console for operator
convenience.

Greater versatility
This machine is well suited for the toughest quarry and
mining applications and for material handling. Due to a
superior dumping height of 3.300mm, it can easily load high
boarded trucks even with a 5.6m bucket, saving valuable
time at the jobsite. With a 40 steering articulation angle
to both sides, the WA500-7 is extremely manoeuvrable in
tight places for faster loading cycles, especially on small
quarry benches.

Convenient Maintenance and Serviceability


The WA500-7 provides easy service access in order to
reduce costly downtime. The new model has increased
cooling capacity, wider cooling fin spacing and a standard
autoreversing fan to help keep the radiator clean. The
machine is equipped with the exclusive Komatsu EMMS
(Equipment Management Monitoring System), which has
enhanced diagnostic features that give the operators
and technicians greater monitoring and troubleshooting
capabilities. EMMS also continuously monitors all
critical systems, preventative maintenance, and provides
troubleshooting assistance to minimize diagnosis and
repair time.
FOR MORE INFORMATION AND CONTACT:
Komatsu Europe
Komatsu Europe International N.V.
Bettina Meeuw Coordinator
Kevin Broman
Komatsu Sales Promotion
Corporate Branding Coordinator
Hanomagstrae 9
Tel.: +32 2 255 24 58
30449 Hanover
eMail: kevin.broman@komatsu.eu
Tel.: +49(0) 511 4509 212
eMail: bettina.meeuw@komatsu.eu
Internet: www.komatsu.eu
www.komatsu-deutschland.de

Quick Specs
Operating weight
Engine power (ISO 14396)

34.335 kg
263kW

Hinge pin height

4.770mm

Dumping Clearance (with 5.6m bucket)

3.300mm

Full turn static tipping load (at 40)

22.680 kg

Issue 01 | 2013

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NEWS & REPORTS


Komatsu Europe International N.V

Komatsu

Hybrid HB215LC-1 Hydraulic Excavator

At bauma 2013

he Komatsu Hybrid HB215LC-1 hydraulic excavator will be showcased at Bauma 2013. It is now
T
available in Europe and worldwide, with more than 1900 Komatsu hybrid excavators owned by
customers and millions hours of field operation logged in. With an operating weight of 21.220 kg and

bucket sizes ranging from 0.8 m to 1.05m the Komatsu HB215LC-1 fits into the large 21tonnes class
of hydraulic excavators and boasts an average of 25% less fuel consumption and CO2 emissions than
a traditional excavator. Its a second generation hybrid machine and a product of groundbreaking
research going back to the beginning of this millennium when Komatsu decided to develop hybrid
technology for construction machinery to a level compatible with full scale serial production.

Cutting-edge technology
The HB215LC-1 offers to customers the benefits
that make the Komatsu hydraulic excavators world
renowned: low operating costs, first class operator
comfort, highest safety standards and extreme reliability.
The cabin, boom and arm, undercarriage and revo frame,
as well as the Look and feel of the new machine are
practically identical as on a standard Komatsu PC210-8.
Controls and wear parts are the same, making it simple
for both owners and operators to profit from the added
value of the HB215LC-1.

The hybrid components and the access to regular


maintenance points were fine tuned on the HB215LC-1.
Komatsus hybrid technology saves an average of 25%
fuel with an equivalent reduction in CO2 emissions when
compared to the standard excavator model. The Hybrid
HB215LC-1 offers power and efficiency along with a
reduced environmental impact.
The HB215LC-1 comes standard
KOMTRAX technology, which
operating information to a secure
wireless technology. Data such as

with the latest


sends machine
website utilizing
operating hours,

The HB215LC-1 is powered by the Komatsu Hybrid


System, which includes Komatsus electric swing motor,
power generator motor, capacitor and a 141 hp (104 kW)
diesel engine. Komatsu developed its revolutionary hybrid
system to work on the principle of swing energy
regeneration and energy storage using the Komatsu
Ultra Capacitor system, which provides fast energy
storage and instantaneous power transmission,
thus significantly reducing fuel consumption.
The kinetic energy generated during the swingbraking phase is converted to electricity that is then
sent through an inverter and captured by the Ultra
Capacitor. This captured energy is discharged very
quickly for upper structure rotation and to assist
the engine as commanded by the hybrid controller
when accelerating under workload conditions.

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NEWS & REPORTS


location, cautions and maintenance alerts are relayed
to the web application for analysis. The KOMTRAX
fleet monitoring system increases machine availability,
reduces the risk of machine theft, allows for remote
diagnosis by the distributor, and provides a wealth
of other information to drive business efficiency and
productivity.

Crossrail project
The first UK sale of the unique Komatsu HB215LC-1
hybrid excavator was completed in July 2013, with
the machines first deployment being the prestigious
Crossrail transport project in Central London.

Issue 01 | 2013

Marubeni-Komatsu Ltd, the sole UK distributor of


Komatsu heavy machinery, supplied five HB215LC-1
machines to Ridgway Rentals, a company based in
Shropshire, in the West Midlands region of England.
Edward Prosser, Marketing Manager at MarubeniKomatsu Ltd said: We are delighted to have completed
the first ever UK sale of this distinct piece of equipment,
and are really excited that its already being used on
such an iconic project as the London Crossrail.
These hybrid excavators are probably the most
reliable and technologically-advanced in the industry
today and truly represent a new generation of machines.
They are designed to provide optimum performance
together with significant fuel savings compared with
conventional excavators. Clients can reduce their
carbon footprint and save money at the same time.

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NEWS & REPORTS

Stuart Jones, Director at Ridgway Rentals, said: With


the Government pledging to embrace new technologies
in a bid to make London significantly greener and to
reduce the citys CO2 emissions by 60% over the next ten
years, it seems apt that this particular piece of equipment
was selected for one of its largest scale projects.
Feedback from our client at the London Crossrail project
is that it performs well and uses a lot less fuel, which
has got to be a win - win for everyone. We are thrilled
to have taken delivery of our first HB215LC-1 hybrids. Its
the only excavator of its kind currently on the market,
and we can offer something different to our customers.
We are very much looking forward to showcasing their
benefits to our clients nationwide.

FOR MORE INFORMATION AND CONTACT:


Komatsu Europe International N.V.
Kevin Broman
Corporate Branding Coordinator
Tel.: +32 2 255 24 58
eMail: kevin.broman@komatsu.eu

Komatsu Europe
Bettina Meeuw Coordinator
Komatsu Sales Promotion
Hanomagstrae 9
30449 Hanover
Tel.: +49(0) 511 4509 212
eMail: bettina.meeuw@komatsu.eu
Internet: www.komatsu.eu
www.komatsu-deutschland.de

Looking ahead
Komatsu plans to expand its hybrid technologies
to larger excavator models and other construction
equipment. As a leading manufacturer, Komatsu will
always introduce new equipment that is specifically
designed to curb environmental impact on the natural
environment of the planet, thereby meeting the
requirements of the times. Komatsu will continue to
strengthen their leadership in innovation for the success
of their customers.

Issue 01 | 2013

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NEWS & REPORTS


Komatsu Europe International N.V

Technology for Your Success!


Komatsus Innovations at BAUMA 2013 - Hall B5

t the BAUMA 2013 international trade fair, in Munich on April 1521 2013, Komatsu Europe
International n.v. will showcase their industry leading technologies, fuel efficient machines and
exclusive products and services, all designed and manufactured to provide customers with an advanced
and complete solution to run a successful business in the earthmoving industry.

Komatsus Innovations
In a world premiere, Komatsu will present a new dozer
and an excavator built around Komatsus revolutionary
concept of intelligent Machine Control (iMC), which can
change the future of the construction business. At Bauma
2013, these 2 exclusive machines will demonstrate in a live
performance how they will help customers enhance their
productivity, reduce costs of operations and improve job
site safety.
On the 4500m indoor stand, Komatsus ground breaking
HB215LC-1 Hybrid Excavator, the first green machine of
its kind, already at work on hundreds of job sites around
the world, will no doubt once again be a main attraction for
all visitors of the Bauma fair. Three other new machines,
with EU Stage IIIB engines (S3B) and featuring the
latest innovations aimed towards improving customer
profitability, will be presented to the public for the first
time: the WA320-7 and WA470-7 wheel loaders, and the
PC138US-10 excavator.

Outside the hall, an additional 1000 m outdoors demo


area will host the 2 new iMC machines. There, a drivers
bar, a Komatsu shop and an interactive excavator simulator
will welcome visitors. Also showcased will be a 56 tonne /
29m mining Komatsu bucket.
A press conference is scheduled on April 16 at 14.00
hrs during which Mr. Noji, President of Komatsu Ltd. will
present his view on the future direction of the company.
Ms Fujiwara, Managing Director and CEO of Komatsu
Europe International says: We all look forward to BAUMA
2013 as an exceptional event where Komatsu can share our
ground breaking concepts and innovations for the success
of our customers with the industry and the world
For more details about Komatsus products and services,
please go to www.komatsu.eu or visit your local
Komatsu sales and service organization.

A total of 28 other machines, representative of the


complete Komatsu range, will be available to the public,
many also recently launched on the market with Komatsus
S3B emission-reducing technology.
All Komatsu services will be highlighted, and visitors will
learn more about how Komatsus high-tech product support
and dealer and customer services such as Komatsu CARE,
Dealer Qualified Used Machines and Komatsu Genuine
Parts can help improve a business. More information will
be given about Komatsu Financial Europe, and a special
space dedicated to KOMTRAX, Komatsus exclusive
wireless monitoring system, and to the latest upgrades
available as standard on Komatsu machines. The mining
corner, and a true cabin of PC8000 mining excavator, will
certainly draw a lot of attention.

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Volvo Construction Equipment

Volvo Construction Equipment


stands for expert knowledge at Bauma 2013

Customer Solutions: A full and diverse range of


customer solutions designed to boost customer profitability.

olvo Construction Equipment demonstrates its expertise in personalized solutions


with an expanding line of innovative customer solutions tailored to increase
availability throughout a machines lifecycle. And dont miss the expanded range of
Volvo Attachments that will be presented at Bauma 2013.

Volvo Construction Equipment is well known for its


machines and their safety, quality and care for the
environment not to mention technology and awardwinning design. But beyond the machines, theres a wide
range of products and services available that support the
complete ownership experience solutions that benefit
machine owners for years following the initial purchase.
Volvo is showcasing the knowledge within its business at
Bauma 2013 and will conduct live interview with its product
and service experts who are on hand to advise customers
throughout the show. From rock to road, Volvo provides a
total solution that caters for every aspect of a machines
productive life from purchase financing, through a
machines lifecycle, until its eventual refurbishment or
disposal.

Issue 01 | 2013

There for you every step of the way


The people behind Volvos products and services are
highly trained from the salespeople in our dealerships
to service technicians in the field and this year they will
take the spotlight. Throughout the day Volvo experts will
take center stage and answer questions about how Volvo
can support customers to help maximize their businesss
profitability throughout the complete machine lifecycle.

Volvo Customer Support Agreements


Volvo CE dealers can offer customers agreements that
are optimized to tune service levels to specific time periods
or conditions such as machine mix, age, application,
or even the degree to which a customer self-services a
fleet. Customer Support Agreements bundle important
aftermarket products and services such as Volvo-trained

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NEWS & REPORTS


service technicians, Genuine Volvo Parts, maintenance
and repairs into one package ensuring optimum uptime,
increased performance, higher productivity and better
cost control.

Genuine Volvo Parts and Volvo


Attachments
Volvo will present an expanded range of attachments
at Bauma; tools that reflect the Volvo brand in terms
of quality. All Genuine Volvo Parts are designed along
with the machines to perfectly complement equipment
performance. The comprehensive range includes kit
solutions, remanufactured parts or application-specific
solutions like attachments and ground engaging tools. And
customer support, warranty parts and service support are
all available through Volvo.

Volvo service technicians


Service once meant responding quickly to a machine
breakdown, but now pre-empting and preventing
breakdowns through advance warning has become even
more important. Frontline Volvo support is a prime reason
customers remain dedicated to Volvo.

Oil analysis
A service to help customers plan maintenance as
well as reduce the risk of unplanned downtime and
expensive repairs. Volvo-trained service technicians can
give machines a thorough health check-up by analyzing
samples of oils in the engine, transmission, hydraulic
system, axles and brakes as well as coolant and fuel
quickly and efficiently through the Volvo laboratory.

Volvo Construction Equipment (Volvo CE) is a major


international company developing, manufacturing
and marketing equipment for construction and
related industries. Ist products, leaders in many world
markets, include a comprehensive range of wheel
loaders, hydraulic excavators, articulated haulers,
motor graders, and soil and asphalt compactors,
pavers, milling machines, compact equipment and
material handling equipment. Volvo CE is part of the
Volvo Group, the worlds largest manufacturer of
diesel engines in the 9 to 18 liter category. The Volvo
Group is one of the worlds leading manufacturers
of trucks, buses and construction equipment, driver
systems for marine and industrial applications,
aerospace components and services. The Group
also provides complete solutions for financing and
related services.

CareTrack
Most new larger machines come with three years of free
activation of the Volvo Construction Equipment telematics
system CareTrack, which provides customers with a
solution that facilitates monitoring of machine health, fuel
consumption and activity. CareTrack is available in most
regions and will continue to expand to new markets. Speak
to our trained dealers on the stand about how to interpret
the valuable data that helps owners maximize productivity
and efficiency.

FOR MORE INFORMATION AND CONTACT:


Volvo Construction Equipment
Steven Lefebvre | Brian OSullivan
External Communications | SE10
London
Tel: int + 32 2 482 5042 | Tel: int +44 77 333 50307
Email: steven.lefebvre@volvo.com | Email: osullivan@se10.com
Internet: www.volvoce.com

MATRIS-analysis
Volvo dealers can provide expert analysis of machine
operating activity via this tool. MATRIS analysis supports
optimized operation by tracking activity characteristics
and identifying opportunities for improvement resulting
in better economy and reduced wear.

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Volvo Construction Equipment

Volvo Penta at Bauma 2013:

A new, exciting Start/Stop function and an update of the


coming Tier 4 Final engine range

Volvo Penta: Volvo Penta highlights Tier 4 Final solution.

hen the doors to Bauma 2013 will open on 15 April, Volvo Penta is ready for an
exciting follow-up of the new Tier 4 Final engine range and for displaying engine
features like the Start/Stop function the latest Volvo Penta innovation that will
help operators to significantly reduce their fuel costs.

The story of the Tier 4 Final engines started in January,


2011, when Volvo Penta introduced its range of engines
compliant with Tier 4 Interim/Stage 3B all based on the
Selective Catalytic Reduction (SCR) technology. They were
well received by the market. But the off-road equipment
industry were also well aware that within less than 3
years they had to go from the Interim stage to the Final
stage a substantial 80% reduction of the NOx from 2.0
g/kWh to 0.4 g/kWh. They were also facing the additional
challenge of re-designing their machines for installing new
engines and after-treatment systems from their suppliers.
Revolutionising.

David Hanngren, Manager Product Planning Industrial


at Volvo Penta, explains: With our new Tier 4 Final engine
range, we will meet our customers primary objectives: no
re-generation, limited installation challenges, continuous
optimised fuel consumption and low operating costs. With
as few and as simple changes as possible, we aim to make
our customers job as easy as possible, and adds: This is
probably the best EGR system in the world.
The light EGR system added to the engines has
provided further emission reduction. It will, at the same
time, help keep the SCR catalyst operating at an optimal
temperature. By avoiding a costly Diesel Oxidation Catalyst
(DOC), installation is greatly simplified.

Volvo Penta chose to keep it simple


To meet the new, stringent emission requirements of
Tier 4 Final, Volvo Penta soon found that the well-tested
and well-proven SCR technology was superior. Apart from
meeting all the new emission standards, it would make
life easier for all the equipment manufacturers already
employing this technology.

Issue 01 | 2013

A new, solid engine range


The Volvo Penta Tier 4 Final engine range for off-road
applications consists of five basic engines. Thanks to the
SCR system it has been possible to meet the new emission
standards with only a limited number of technical changes.

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NEWS & REPORTS


Here, the component commonality of the engines is
particularly valuable to OEMs who include several engine
sizes in their product applications.

from long and costly downtimes in the long term, but


also to tailor the agreement in accordance with specific
conditions and requirements.

All the engines in the new range will be on display at


Bauma 2013, 1521 April, in Munich. They will also be ready
for delivery in 2014 but already today they are ready for
the OEMs drawing-boards.

Mining industry people attending Bauma will most


certainly focus on Volvo Pentas new range of engines
approved for underground mining applications; nine
Tier 2 engines and nine Tier 4i engines with outstanding
ventilation rates.

More Volvo Penta news at Bauma

A fourth novelty is the Volvo Penta Oil Analysis an


easily performed analysis that will enable operators to
increase the intervals between services from every 500
hours to every 1,000 hours a massive improvement which
will pay off already in the short term.

At Bauma, Volvo Penta will also introduce the new,


automatic Start/Stop Function for industrial equipment. It
turns off an idling engine after a pre-set time span, and
when the driver activates any machine control the engine
starts immediately and the work can continue. This Volvo
Penta innovation will help operators to reduce their fuel
costs with up to 5%!
Volvo Penta will also launch the new Industrial Extended
Coverage, IXC a programme that allows operators and
equipment manufacturers to not only guard themselves

FOR MORE INFORMATION AND CONTACT:


Volvo Construction Equipment / AB Volvo Penta
ke Edman
phone: +46 (0) 31 3225190,
eMail: ake.edman@volvo.com
Internet: www.volvoce.com

Volvo Penta: Volvo Penta unveils innovative stop-start feature.

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Liebherr-International AG

World Premiere at the 2013 Bauma:


Liebherr TA 240 Articulated Dump Truck

ith its new TA 240 Litronic, Liebherr is using the 2013 Bauma trade fair to introduce another
model in its articulated dump truck range. The successful launch of the 30-tonne TA 230
is now followed by a model in the 40-tonne category Liebherrs response to growing market
demand for complete programmes from a single source for the loading and transport of various
materials.

As with the TA 230 Litronic, the model designation


includes the payload in metric tons. With a load capacity
of 40 t and a dumper body volume of 27 m with rear flap
the TA 240 has been ideally planned for the fast, costeffective transport of large volumes of bulk material. The
dumper body is specially shaped to speed up discharge of
the contents.

Powerful driveline, innovative retarder


The three HD axles have been designed for strength and
stability, and are the ideal basis for the exceptionally highperformance 6 x 6 driveline with automatic transmission,
torque converter and converter lockup clutch. This new
articulated dump truck is driven by a powerful Liebherr D
9508 V8 diesel engine with SCR system and a displacement
of 16.2 litres. It complies with Stage IIIB / Tier 4i exhaust
emission limits and has an output of 350 kW (476 hp). With
this power available, the dump truck can reach speeds of
up to 57 km/h on level surfaces. When reversing, maximum
speed is limited electronically to 16 km/h.

Issue 01 | 2013

A high-performance retarder makes the vehicle safer


and more convenient off-road, and also helps keep
operating costs low. The retarders braking action can be
continuously varied and the desired value preselected.
This is a very useful option, for instance if the vehicle is
regularly used on the same downhill route. As soon as the
driver takes his foot off the accelerator pedal, the engine
brake and retarder are activated with no delay and with
the braking effect previously selected. At the end of the
downhill gradient the retarder shuts down automatically,
but the previous braking level remains available when
selected again.
The wet-type oil-cooled multi-disc brakes are operated
only when the TA 240 comes to a halt for loading and
discharging or if an emergency brake application is
needed.
All maintenance and servicing work on the new TA 240
can be completed with minimum loss of time. The drivers
cab and the engine hood can be tilted electro-hydraulically
for quick, safe access to all maintenance points.

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Functional design, bold styling

Liebherr components for key technologies

The new Liebherr TA 240 dump truck catches the eye


immediately with its striking design and the drivers cab
with its exceptionally large window area. The restyled,
extremely spacious cab offers the driver maximum comfort
and convenience, and complies with the ROPS/FOPS safety
standard. Visibility is excellent through the large windows,
so that the dump truck can be positioned quickly and safely
for loading or discharge. The ergonomically designed, airsprung drivers seat is standard equipment and can be
adjusted individually to suit the drivers size and weight.

As on many other Liebherr construction machines, key


technical functions on the new TA 240 are performed by
components developed and manufactured at various
Liebherr competence centres.

The controls for the automatic transmission and retarder,


and also the tipping control levers, are very responsive
in operation, so that precision control of the dump truck
presents no problems. Thanks to the well laid out, easily
legible display unit with touch-screen function, an
innovative Liebherr PME electronic component developed
in-house, the driver can check the vehicles operating
condition at any time without being distracted from the
driving task. As an option, the display can show images
from the standard Liebherr front- and rear-view cameras
or details of current temperature, engine speed, air
conditioning, daily operating hours, number of discharge
movements or number of operating hours.
A further feature contributing to comfort are the highquality spring-damper units on the front axle, which are
rated to withstand the most arduous operating tasks. The
level of ride quality that they provide also helps maintain
the drivers concentration during long, demanding work
sessions.

Issue 01 | 2013

Liebherrs reliable hydraulic cylinders, which have


proved highly successful in tough construction-machinery
operating conditions, are used to perform tipping and
steering movements on the new articulated dump truck.
Thanks to its powerful hydraulic dumper body actuating
rams, the TA 240 can discharge its full load reliably in only
12 seconds and return to the lowered position within a
further 8 seconds. Equally successful in ensuring directional
stability and reliable steering in all circumstances, even
when crossing very difficult terrain, are the steering rams;
these too are developed and manufactured in-house by
Liebherr
Electrical and electronic items such as wiring harnesses,
cameras, the touch-screen display, other controls and the
central machinery control unit are also of Liebherrs own
manufacture.

FOR MORE INFORMATION AND CONTACT:


Liebherr-Hydraulikbagger GmbH
Thomas Buerle
Tel.: +49(0) 73 54 80-73 64
Fax: +49(0) 73 54 80-75 35
eMail: Thomas.Baeuerle@Liebherr.com
Internet: www.Liebherr.com

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Liebherr-International AG

Liebherr is exhibiting its large IIIB-generation


Wheel Loaders at the 2013 Bauma

t the 2013 Bauma, Liebherr is presenting its new IIIB generation of large machines for the
first time to users worldwide. These wheel loaders were first shown to a wider public at the
Intermat in April 2012.

Higher performance, enhanced stability


The L 550 and L 556 have a redesigned engine
compartment with the diesel engine installed transversely.
This gives them an even more compact layout, and
makes all the principal maintenance points accessible
from ground level. The engine output of the L 576 and L
580 models has been increased, and all the large newgeneration machines have an optimised tipping load limit
that further improves productivity and stability.
In addition to the Z-bar linkage for standard operating
tasks, Liebherr supplies industrial lift arm. No other
manufacturer offers both lift arm versions in every machine
category at no extra cost.
The geometry of the industrial lift arm has been specially
chosen for high load moments and ample force in the

Issue 01 | 2013

upper lifting area. As a result, exceptionally heavy loads


can be handled. The pattern of movement is parallel over
the entire lifting range. The industrial lift has a hydraulic
quick coupler as standard equipment.

LPE driveline boosts performance and


economy
For the IIIB generation, Liebherr continues to use
hydrostatic drive concept together with another Liebherr
development: Liebherr Power Efficiency (LPE). This is an
electronic mapped-characteristic control system that
increases the machines handling power and keeps fuel
consumption to a minimum. Compared with other machines
in similar size categories, the innovative driveline concept
cuts fuel consumption by as much as 25%.

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Less fuel is needed for the same performance, and tyre
and brake wear are reduced.
The LPE system influences engine management proactively: the machines software receives an electronic
accelerator-pedal position signal and computes the most
efficient way of carrying out the operators wishes. LPE
optimises interaction of the driveline components in terms
of swiftness and sensitive control of the machine.
The new-generation diesel engines are now even more
environmentally friendly, with many other improvements,
too: precision common-rail fuel injection optimises the
combustion process and reduces pollutant emissions.
Exhaust emission control is by means of a diesel oxidating

FOR MORE INFORMATION AND CONTACT:


Liebherr-Werk Bischofshofen GmbH
Maria Graffius
Tel.: +43(0) 50809 11-543
Fax: +43(0) 50809 17-741
eMail: Maria.Graffius@Liebherr.com
Internet: www.Liebherr.com

Issue 01 | 2013

catalytic converter combined with a diesel particulate filter.


In most situations, this filter can be actively regenerated by
burning off deposits during operation of the machine, and
the task in hand continued without interruption.

Straightforward maintenance, ease of control


Cleaning and servicing are easier than ever before on
the new IIIB generation of wheel loaders. The operator can
reach the maintenance points for the principal components
from ground level. Cleaning and maintenance work has
been reduced to a minimum: the radiator assembly is again
installed directly behind the cab, where air with a low dust
content can be drawn in.
The operator will appreciate the functional efficient,
ergonomically correct cab layout. The operators seat with
horizontal side-to-side suspension, available as an optional
extra helps reduce operator fatigue. New cab mounts have
been developed to lower the level of noise and vibration
inside the cab. As far as outside noise emissions (sound
power levels) are concerned, Liebherr is traditionally
among the leaders; its machines operate well below the
permitted limits.

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Liebherr-International AG

AT THE Bauma 2013: Liebherr exhibits

revised Design of Midsize Wheel Loaders

t the 2013 Bauma, visitors will have a first opportunity to see Liebherrs redesigned midsize
range of wheel loaders. The L 524, L 528, L 538 and L 542 conform with IIIB / Tier 4i emission
standards.
These Allrounders on the wheel loader scene have
been further optimised in the efficiency and safety areas
in particular. Their performance and stability, their engine
output and the power hydraulic ratings are now higher.
Throughout their product range, the tipping load limits
have been raised and the structural steelwork reinforced
to make the machines even stronger.

Many innovations for greater productivity


The LIKUFIX hydraulic quick-change system that has
proved so successful on Liebherr hydraulic excavators is
now available for midsize Liebherr wheel loaders. Working
attachments can be detached and attached in a matter
of seconds, working directly from the wheel loaders cab.
The hydraulic lines are connected fully automatically in the
same way, with no hydraulic fluid leakage.

Issue 01 | 2013

As in the past, the purchaser can choose at no extra


cost between a Z-bar linkage for standard operations,
or a parallel linkage for industrial applications. This way
the machines specification can be ideally matched to the
intended tasks.
For the new midsize wheel loaders, Liebherr has
retained its hydrostatic drive concept, and combined it with
Liebherr Power Efficiency (LPE) as a means of boosting the
machines handling capacity and economy. Compared with
other wheel loaders in this size category, the innovative
driveline concept cuts fuel consumption by as much as
25%. The wheel loader needs less fuel, and tyre and brake
wear are reduced.
A Liebherr development, the LPE system influences
engine management pro-actively: the machines software
is supplied with the accelerator-pedal position signal and

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then computes the most efficient means of implementing
the operators instructions. LPE optimises interaction of
the driveline components.
Liebherrs design concept for its midsize wheel loader
series ensures comparatively high handling capacities,
since high tipping loads are possible despite the machines
low tare weight.
The new generation of diesel engines is now even more
environmentally friendly and there have been many other
improvements, too: precision common-rail fuel injection
optimises the combustion process and reduces pollutant
emissions. Exhaust emission control uses a diesel oxidating
catalytic converter combined with a diesel particulate filter.
In most situations, this filter can be actively regenerated by
burning off deposits during operation of the machine, and
the work in progress continued without interruption.

Safety, ease of control, straightforward


maintenance
These Allrounders now have -larger cab windows;
the roof has been shortened and the upper part of the
windscreen extended farther back. To the left and right
of the steering column, the cabin trim has been lowered
and replaced by glass. All-round visibility is therefore even

Issue 01 | 2013

better on these new models. A fold-out window for the


cabs door is an option, and makes it possible to open the
window completely. The cab is larger and safer, with even
higher standards of comfort and convenience.
The new wheel loader generation had excellent ride
quality and even more stable, accurately controlled steering
response. This is due to the two steering cylinders installed
as standard on all these new-generation Allrounder
models. Design changes to the vehicles frames increase
stability even when travelling at quite high speeds. More
severe surface irregularities are compensated for by the
rear swing-axle suspension.
All maintenance points can be easily and safely reached
from ground level by opening just one single hood. This is
possible because the Allrounders diesel engine has been
turned through 90. The transverse location of the radiator,
with an air-intake in its customary position directly behind
the cab reduces the amount of cleaning work needed,
because the air drawn in contains less dust. Cooling
system performance has also been uprated to suit the new
technological requirements.

FOR MORE INFORMATION AND CONTACT:


Liebherr-Werk Bischofshofen GmbH
Maria Graffius
Tel.: +43(0) 50809 11-543
Fax: +43(0) 50809 17-741
eMail: Maria.Graffius@Liebherr.com
Internet: www.Liebherr.com

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Liebherr-International AG

Liebherr introduces
the 22-tonne R 922
Crawler Excavator at
the 2013 Bauma

t the 2013 Bauma Liebherr is presenting its new R 922 crawler excavator, which is to supersede
A
the previous R 906 model. Together with the R 918 and R 926 crawler excavators that are to be
seen on partner stands, the 22-tonne R 922 is a member of the newly developed product range with
up to 30 tonnes service weight. Its Liebherr diesel engine with oxidating catalytic converter has a
rated output of 105 kW (143 hp) and complies with Stage IIIB exhaust emission limits.

The new 22-tonne R 922 Crawler Excavator


The new R 922 is designed for earthmoving and
drainage work. Like all the new-generation excavator
models, it is equipped with integrated excavator system
technology for rapid, smooth working movements. In
order to make the necessary flow volume available
quickly and without one consumer significantly
affecting another, and to ensure optimal use of the
available energy, the Dual Circuit Positive Control
hydraulic system is used. This allows the machine
operator to save energy compared with other systems,
since it reduces or in some cases entirely eliminates
pressure losses. The driver benefits from the natural,
harmonious movement cycles made possible by the
load-dependent volume distribution principle.
The R 922 exhibited at the Bauma is equipped with
Liebherrs Likufix quick-coupling system, which has
enjoyed many years of popular success. The extensive
range of backhoes and add-on tools, and Liebherrs
own patented bucket tooth system, enable the crawler
excavators productivity to be increased still further.

Issue 01 | 2013

The steelwork has been functionally optimised


to withstand continuously increasing demands for
trouble-free operating life. The cruciform undercarriage
increases stability and disperses stresses more
effectively. The centre section and side members are
designed to make cleaning quicker and easier. The
tractive force of 190 kN makes the excavator highly
manoeuvrable, even over difficult terrain. Higher
grabbing force, a breakout force of 123 kN and a digging
force of 149 kN increase the performance of the R 922
still further.
The R 922s cab sets new standards of ride quality
and ergonomic control layout in its class. Low
noise levels, an agreeable sense of space and fully
automatic air conditioning as standard equipment
guarantee the driver a pleasant place of work. Easily
reached controls and a colour touch-screen that can
be operated intuitively make the working environment
even more agreeable. The windscreen can be fully
opened for quick, easy communication with people

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nearby, especially on drainage work. The reinforced cab
complies with ROPS regulations and ensures optimal
safety for the driver. As a further means of making work
safer, a rear-view camera is integrated into the ballast
weight as standard equipment; its high-resolution image
is displayed on the touch screen.
Maintenance points on the new R 922 can be reached
from ground level. This reduces the time needed, and
makes the task safer for maintenance personnel. A
Liebherr central lubricating system is also standard;
its programmed lubrication is in accordance with the
excavators maintenance schedule and means that
valuable time is saved. The LIDAT data transmission
system permits more effective maintenance planning
and management of the machine fleet.

FOR MORE INFORMATION AND CONTACT:


LLiebherr-France SAS
Catherine Pierrat
Tel.: +33(0) 389 21-3070
Fax : +33(0) 389 21-3793
eMail: Catherine.Pierrat@Liebherr.com
Internet: www.Liebherr.com

At the Bauma the R 922 is exhibited with a gooseneck


boom, a 2.7 m long dipper stick and an LC undercarriage.
Even with 600 mm wide track pads, it does not exceed an
overall width of 3.0 metres for road transport.

Issue 01 | 2013

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Liebherr-International AG

Liebherr is exhibiting the 350-tonne R 9400


Mining Excavator at the 2013 Bauma

t the 2013 Bauma trade fair in Munich, Liebherr is presenting the face shovel versionof its 350A
tonne R 9400 mining excavator. With a 22-m bucket as standard equipment, the R 9400 is the ideal
machine for loading a mining truck fleet in the 136 tonnes class. The R 9400 is available with either a
diesel engine or an electric motor, for optimal flexibility in a wide variety of applications.

The 350-tonne R 9400 Mining Excavator


There are currently over thirty R 9400 hydraulic mining
excavators operating in four countries. The latest R 9400
commissioned in a Ghanaian gold mine is the first model
in face shovel configuration. The excellent productivity
that the R 9400 is known for in backhoe configuration is
expected in in face shove configuration.
The production-tailored attachment kinematics
combined with a mining-optimized bucket shape ensure
the highest crowd and breakout forces. Even under tough
conditions the R 9400s high digging force allows easy
bucket penetration and high bucket fill factors to achieve
high productivity.
The R 9400 follows the Liebherr design philosophy of
maximizing the machines performance by improving the
efficiency of all individual subsystems. Engineered for
optimum serviceability the machine is designed to ensure
maximum uptime.

Issue 01 | 2013

Designed for hard application, the R 9400s heavy duty


3-piece fatigue-resistant undercarriage provides efficient
superstructure weight distribution and reduces ground
bearing pressure enabling the necessary stability and
reliability.

Innovative hydraulics, high-performance


drivelines
Optimizing electrical, mechanical and hydraulic power
distribution, the Litronic Plus System allows for easy control
even when simultaneous movements are required. Every
attachment cylinder is fitted with the patented Liebherr
Electronic Damping System which provides controlled
end-cushioning for fast and smooth machines motions.
Intelligent and power-oriented energy management
diverts the pump flow during boom lowering, allowing
other cylinder motions to operate unimpeded.

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The R 9400 is powered by a Cummins QSK50 diesel engine
that complies with USA/EPA Tier 2 exhaust emission limits
and has a rated output of 1250 kW (1675 hp).
The electric-motor drive also available is an economically
viable alternative in a number of application areas, for
instance machines intended for work in arctic regions.

Advanced Mining Academy

Well-equipped cab, simple maintenance

Weiterbildungsprogramm
Mining

The R 9400 has a wide, spacious cab that provides the


operator with the comfortable working conditions needed
for maximum productivity. Mounted on vibration dampers,
it also reduces the noise level and creates an quiet
environment that promotes the excavator operators own
performance.

Eine praxisorientierte modulare


Ausbildung fr Fach- und
Fhrungskrfte der Bereiche
Mineralische Rohstoffindustrie
Maschinenindustrie
Rohstoffhandel
Finanzsektor
Dienstleistungssektor

In addition to its excellent ergonomic design, the cab


provides maximum protection for the operator. The robust
steelwork of low-stress design and the safety-glass
windows comply with the FOPS standard and protect
the operator against falling material. For maximum safety
there are several easily reached emergency stop buttons
at ground level, in the cab and in the pump and engine
compartments.
All machine accesses have been optimized. The R 9400s
upperstructure is accessible via a powered 45 stairway
fitted with handrails and the service drop down flap
provides easy access to the main servicing features. Fuel,
engine & hydraulic oil, grease, windshield wash water can
be refilled and drained from ground level.

Kontakt:

FOR MORE INFORMATION AND CONTACT:

AMA - Advanced Mining Academy


Albrecht-von-Groddeck-Str. 3
38678 Clausthal-Zellerfeld
Telefon: +49 (0) 53 23 - 98 39 38
Telefax: +49 (0) 53 23 - 96 29 908
eMail: academy@advanced-mining.com

Liebherr-Mining Equipment Colmar SAS


Swann Blaise
Tel.: +33(0) 369 49-2199
Fax: +33(0) 369 49-2279
eMail: Swann.Blaise@Liebherr.com
Internet: www.Liebherr.com

ANZEIGE

www.advanced-mining.com/academy

Issue 01 | 2013

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NEWS & REPORTS


Liebherr-International AG

LB 44 Rotary Drilling Rig completes


Liebherrs Range of Products for
Deep Foundation Applications

he LB 44 rotary drilling rig newly presented at the Bauma 2013 is the


latest development in Liebherrs range of deep foundation products
and expands the LB series at the upper end of the scale. Based on its many
years of experience and extensive know-how, Liebherr is reacting to the
need for larger, more powerful machines of this type by presenting the
LB 44.
The LB 44 rotary drilling rig weighs approx.
160 tonnes and has been designed for drilling
diameters of up to 3 m and drilling depths of
maximum 92 m. The rig is driven by a V8 diesel
engine offering 505 kW (677 hp) and complying
with the exhaust certification stage 3B.
Possible applications of the LB 44 include
Kelly drilling, drill-ing with double rotary head,
continuous flight auger and full displacement
tool. The powerful rope crowd system with
ap-prox. 56 t pull force allows utilisation of
the entire length of the leader. This provides
the operator with maximum perfor-mance and
reliability even with the most difficult soils and
extreme operational conditions.

High mobility at and between


jobsites
Distinguishing advantages of the new rotary
drilling rig are its easy transportation and
the short period of time between set-up and
operation. As the leader can be folded back
for transportation with all hydraulic hoses
connected, no disassembly is required when
moving between two jobsites. Subsequently,
the LB 44 can be set up rapidly using the quick
assembly system - this process barely requires
more time than for smaller machines.
If required the LB 44 can be disassembled
into single parts weighing max. 40 tonnes.
Thus, the rotary drilling rig can be transported
throughout the world without any problems.
For the basic design of the rig Liebherr
remains true to its proven principles. This
includes a large operating area thanks to
parallel kinematics. Another aspect relates to
the direct mounting of all winches on the leader.
On the one hand, this allows for a direct view
from the operators cab to the main winch and,
on the other hand, ensures that the ropes do not
move during leader adjustment. Moreover, the
undercarriage provides more stability thanks
to long crawlers but still provides nearly the
same small swing radius as the smaller rigs of
the same product line.

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FOR MORE INFORMATION AND CONTACT:

Liebherr-Werk Nenzing GmbH


Wolfgang Pfister
Tel.: +43(0) 50809 41-444
Fax: +43(0) 50809 41-500
eMail: Wolfgang.Pfister@Liebherr.com
Internet: www.Liebherr.com

Innovative rotary drive of BAT series


The innovative BAT rotary drive of the new LB 44 offers
a torque of 510 kNm. The main advantages of the hydraulic
drive manufactured by Liebherr are automated torque adjustment, continuous speed optimization and four electronically adjustable speed ranges. Further advantages of this
rotary drive are its simple structure, its low maintenance
re-quirements and, above all, its exceptional efficiency.

Issue 01 | 2013

Like all Liebherr piling and drilling rigs the LB 44 is also


fitted with the proven Litronic control system and thus offers
a multitude of programme options for the various drilling
methods as well as for clearly displayed information on
service requirements and the condition of the machine.
The use of many components manufactured by Liebherr
guarantees the customer a product of highest quality. This
is completed by the rigs robust design in order to provide a
long service life of the new LB 44 rotary drilling rig.

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Liebherr-International AG

Liebherr Components at the 2013 Bauma

he Components division of the Liebherr Group has its own stand at the 2013 Bauma, (Stand
A4/115 in Hall 4). The exhibits from the mechanical, hydraulic and electrical drive systems
areas have been developed and manufactured at various Liebherr competence centres, and
demonstrate the exceptional bandwidth of the divisions product programme.

Common-rail fuel injection systems from


Liebherr
A highlight on the Components stand are the new
common-rail fuel injection systems, with their own enginemanagement control units. These systems are already
standard equipment on Liebherr engines with between
four and twelve cylinders, but can be adapted for use on
other manufacturers diesel engines. Liebherr common-rail
systems are notable for exceptionally low fuel consumption
and efficient combustion, both factors that reduce exhaust
emissions.

Issue 01 | 2013

New generation of diesel engines


At this years Bauma, trade and other visitors will be able
to see for the first time the latest generation of Liebherr
diesel engines that comply with the EU stage IV / EPA Tier
4 final exhaust emission limits that come into force in 2014.
Liebherr uses Selective Catalytic Reduction (SCR) only
on these engines, an innovative technology that makes
particulate filters unnecessary.

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LiView: a hydraulic cylinder position
measuring system
Also to be seen at the Bauma is LiView, an innovative
electro-hydraulic system for the precise, reliable position
measuring of hydraulic rams and cylinders in all size
categories. The actual position is determined to an
accuracy that can be as high as +/- 1 mm. LiView is strongly
built and therefore suitable for installation on construction
machinery and mining equipment. Based on the position
data detected by LiView, construction machines movement
sequences can be automated and their performance
potential and ease of control greatly enhanced.

Control system for small mobile machines


In the electronics area, Liebherr is exhibiting a control
system for small mobile machines. The system consists
of a compact control unit a new development with
display, keypad and camera. It is a modular system
based on familiar industrial standards, and is suitable for
construction, agricultural and forestry machines and also
for road construction machinery and communal vehicles

on which high standards of freedom from vibration and


shock together with resistance to temperature changes
and contamination have to be complied with. The display
can be supplied with a multi-image function capable of
showing signals from up to four cameras simultaneously.

New series-production driveline components


In the hydraulic pump and motor, large anti-friction
bearing and transmission areas, a notable development
is the new series-production range of travel-gear drives
(FAT) with hydraulic motors. This series, developed
and manufactured by Liebherr itself, consists of eleven
transmissions in successive sizes, from FAT 325 to FAT 1600;
they are available in crawler-crane or crawler-excavator
versions. The corresponding Liebherr hydraulic motors of
axial-piston type, with swashplate pitch adjustment, are
supplied with these units and matched optimally to them.
They ensure high levels of overall efficiency within compact
dimensions, and an excellent power-to-weight ratio.

FOR MORE INFORMATION AND CONTACT:


Liebherr-Component Technologies AG
Simone Stier
Tel.: +41(0) 56 296 43 27
Fax: +41(0) 56 296 43 01
eMail: Simone.Stier@Liebherr.com
Internet: www.Liebherr.com

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BAUER Maschinen GmbH

The Bauer BG range of rotary drilling rigs:

The Premium Line concept


At Bauma 2013 BAUER Maschinen GmbH will be launching its new Value Line and Premium
Line classification of BG drilling rigs. The Value Line is optimized for kelly drilling. The
Premium Line, as the name suggests, is a high-end range incorporating multifunction rigs for
a wide variety of applications.
The Premium Line range extends from the BG 12 up to
the BG 50. It enables all rotary drilling techniques to be
implemented, including kelly drilling with and without a
casing oscillator, the classic CFA (continuous flight auger)
system and CCFA (cased continuous flight auger) drilling,
as well as soil displacement pile drilling. The Premium
Line rigs can also be used without problem to carry out
all kinds of ground improvement techniques, such as
CSM (cutter soil mixing), single or multiple soil mixing,
or deep vibration. They can also be fitted with BC trench
cutters. This makes the rigs suitable as a platform for all
commonly employed specialist foundation engineering
techniques, and enables them
to adapt to a wide variety of
different soil types based on a
broad range of tools.

Issue 01 | 2013

All Premium Line rigs can be fitted with a Tier IV i


engine conforming to the highest exhaust emission
standards, though a standard Tier II or III engine is still
available for all models intended to be used in markets
where emissions are not regulated. The base carrier units
for the Premium Line are specified to attain the lowest
noise emission values in their class. Their specification
ensures compliance with the very latest environmental
standards.

BAUER rotary drilling rig BG 42

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The main winches for the Premium Line rigs feature
high pulling forces and wide drums. A drilling and
drawing assist function aids handling in Single-pass
drilling operations. State-of-the-art electronic systems
make the rigs easy to control and highly responsive.
The new Bauer B-Tronic Generation 4.1 is an enhanced
variant, featuring monitoring of the winch pull and
hoisting speed, a torque indicator and error message
display as well as a diagnostic assist. The BG Premium
Line models are also equipped as standard with the
Bauer kelly visualization system, which provides
operators with full assistance to ensure the kelly bar is
operated optimally and with low wear. A tablet PC with
built-in wireless functionality now likewise comes as
standard in the new Premium Line cab.
One of the designers key objectives was to optimize
all the safety features. The rigs now incorporate
fall guards, an integrated ladder to access the
uppercarriage and handrails on all walkways, as well
as walk-on platforms on top of the uppercarriage. The
service hatches on the side of the uppercarriage are of
lift-up design. The counterweight disks can be variably
stacked.
Great attention was paid to ease of handling and to
optimum health and safety assurance. The rigs enable
operators to work in a stress-free environment, without
becoming fatigued. A new cab design and state-ofthe-art, ergonomic layout provide the ideal degree of
visibility for operators. This is also aided by an array
of cameras, enabling operations to be monitored onscreen. Rear-view cameras permit operators to monitor
the rear end and right-hand side of the rig, and the main
winch reel-in is likewise monitored by a camera.

The BAUER Maschinen GmbH


Leading-edge technology for specialist
foundation engineering
The companies of the Schrobenhausen-based Bauer
Maschinen Group are showing numerous novelties at
Bauma 2013 on the newly built open-air exhibition site
north, stand number FG N 520. BAUER Maschinen GmbH
has been continually expanding its product range over
recent decades, and together with all its subsidiaries
it will be presenting the broadest offer in the specialist
foundation engineering equipment sector.
The core Bauer Maschinen products are the drilling
rigs of the BG series and the range of trench cutters.
New products are once again being presented by
KLEMM Bohrtechnik GmbH, with its anchor drilling
rigs and jet-grouting systems. RTG Rammtechnik
GmbH provides Bauer with a competence centre in the
manufacture of a wide variety of leader systems. MAT
Mischanlagentechnik GmbH produces suspension
mixers and treatment plants, while PRAKLA Bohrtechnik
GmbH is a manufacturer of well drilling rigs.

BAUER rotary drilling rig BG 42

FOR MOPRE INFORMATION AND CONTACT:


BAUER Maschinen GmbH
D-86529 Schrobenhausen
Tel. +49(0) 8252 97-0
Dipl.-Ing. Manfred Schpf
Tel.: +49(0) 8252- 97 1302
eMail: Manfred.Schoepf@bauer.de
Internet: www.bauer.de

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BAUER Maschinen GmbH

The Bauer

Deep drilling rig RB-T 90


PRAKLA Bohrtechnik GmbH is presenting a deep drilling rig
designated RB-T 90. The company has sold six of the universal
drilling rigs to China. They are designed to sink emergency
rescue shafts to reach trapped miners quickly and safely.
A key feature of the newly developed machines is their great mobility: Built on a
truck trailer, they can be towed quickly to any location where they may be needed.
The rigs are being built in the Bauer Maschinen plant at the corporate headquarters
in Schrobenhausen, Bavaria. RB-T 90 drilling rigs offer a maximum hook load
capacity of 90 tonnes. The maximum small-diameter drilling depth is 3,000 metres.
With 700 millimetres diameter, bores can be sunk down to a depth of 1,500 metres.

The BAUER Maschinen GmbH


Leading-edge technology for specialist foundation engineering
The companies of the Schrobenhausen-based Bauer Maschinen Group are showing numerous
novelties at Bauma 2013 on the newly built open-air exhibition site north, stand number FG N 520.
BAUER Maschinen GmbH has been continually expanding its product range over recent decades, and
together with all its subsidiaries it will be presenting the broadest offer in the specialist foundation
engineering equipment sector.
The core Bauer Maschinen products are the drilling rigs of the BG series and the range of trench
cutters. New products are once again being presented by KLEMM Bohrtechnik GmbH, with its anchor
drilling rigs and jet-grouting systems. RTG Rammtechnik GmbH provides Bauer with a competence
centre in the manufacture of a wide variety of leader systems. MAT Mischanlagentechnik GmbH
produces suspension mixers and treatment plants, while PRAKLA Bohrtechnik GmbH is a manufacturer
of well drilling rigs.

FOR MORE INFORMATION AND CONTACT:


BAUER Maschinen GmbH
D-86529 Schrobenhausen
Tel. +49(0) 8252 97-0
Dipl.-Ing. Manfred Schpf
Tel.: +49(0) 8252- 97 1302
eMail: Manfred.Schoepf@bauer.de
Internet: www.bauer.de

Deep drilling rig RB-T 90

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Atlas Copco Underground Rock Excavation

Atlas Copco:

The new Boomer E - series

The Boomer XE3 C from Atlas Copcos new


Boomer Series offering simplicity, ergonomic
design, high performance and the widest range of
rock drills in the mining industry.
(Photo: Atlas Copco)

ith an improved user interface, including a new intuitive touchscreen, and user-friendly design,
the next generation of Rig Control System is here today.

Comfortable and environmental


Operator comfort, safety and environmental care also
get priority. For example, the FOPS certified cabins are
air-conditioned and ergonomically designed featuring
the latest operator seat and controls. In the drill rig, the
operator is in focus.

The operator should feel good in order to make a good


job with high productivity. The large 3- and 4-boom rigs
offer a new improved and more ergonomic chair for the
operator. The arm rests have a flat design with just two
multi-functional joysticks instead of four.

The series offers an upgraded control system


with a user-friendly interface, a larger (15-in),
intuitive touch screen, just two multi-functional
joysticks instead of four and the latest rig
support planning software - Underground
Manager (Photo: Atlas Copco)

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Carbon emissions have also been reduced to a minimum
as the diesel engines are needed for moving the rigs
around the site while electricity is used for drilling. The
rig has stage 3B/Tier4i diesel engines as standard and
biodegradable hydraulic oils are offered as options. The
rig can also be equipped for dry-drilling systems.

Underground Manager
All over the world the demand for documentation and
follow-up are increasing. This led us to create the new
underground manager, which takes planning and evaluation
to a higher level. With the underground manager you can
get support to all kind of underground machines from Atlas
Copco. The user interface is new, modern and easy to use.
The system contains a new drill plan generator, complete
3D view of the tunnel, smart, interpolation of contours and
improved log- and report function.
- With these improvements, we are confident that the
new Boomer series offers one of the most powerful and
productive underground mining rigs and tunneling rigs on
the market. Says, Johan Jonsson, Product Manager at
Atlas Copco Underground Division.
The new Boomer rigs will be available via Atlas Copcos
own worldwide sales organization from 2013.

FOR MORE INFORMATION AND CONTACT:


Atlas Copco MCT GmbH
Product Manager
Johan Jonsson
Phone: +46 (0)70 811 0491
Mobile: +46 (0)70 811 0491
eMail: johan.jonsson@se.atlascopco.com
Internet: www.atlascopco.com
Project Leader Marketing Communications
Elisabeth Meyer
Phone: +46 (0)19 670 7019
Phone: +46 (0)70 670 8267
eMail: elisabeth.meyer@se.atlascopco.com
Internet: www.atlascopco.com

Atlas Copco is an industrial group with world-leading positions in


compressors, expanders and air treatment systems, construction
and mining equipment, power tools and assembly systems. With
innovative products and services, Atlas Copco delivers solutions
for sustainable productivity. The company was founded in 1873,
is based in Stockholm, Sweden, and has a global reach spanning
more than 170 countries. In 2011, Atlas Copco had 37 500 employees
and revenues of BSEK 81(BEUR 9).
Atlas Copco Underground Rock Excavation gehrt zum
Geschftsbereich Bergbautechnik von Atlas Copco. Diese
Abteilung entwickelt, fertigt und vermarktet eine breite Palette
an Tunnel- uis a division within Atlas Copcos Mining and Rock
Excavation Technique business area. It develops, manufactures,
and markets a wide range of tunneling and mining equipment
for various underground applications worldwide. The division
focuses strongly on innovative product design and aftermarket
support systems, which give added customer value. The divisional
headquarters and main production center is in rebro, Sweden.

The Boomer XE3 C from Atlas Copcos new


Boomer Series offering simplicity, ergonomic
design, high performance and the widest range of
rock drills in the mining industry.
(Photo: Atlas Copco)

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Atlas Copco Surface Drilling Equipment

Atlas Copco:

Cut high fuel cost and increase productivity with


Atlas Copcos new drill rig FlexiROC T45

t Bauma 2013 Atlas Copco launches its new tophammer surface drill rig, the FlexiROC T45,
along with its new rock drill COP 3060. As the name suggests, this new rig is flexible yet
uncompromising when it comes to fuel efficiency, while the new rock further drill enhances
drilling capacity. The FlexiROC T45 is a production workhorse, just like the ROC F9 before it, but
outstandingly fuel-efficient and even more productive.

At the outset of development, demands were


high for this new drilling rig. Not only was it
expected to be incredibly efficient and productive,
but also it was to be built on a tried and trusted
platform that would provide high-availability
and a wide area of use for both large and small
applications. Naturally, it had to be extremely
fuel-efficient.

FlexiROC T45 with folding boom and the COP


2560 rock drill and T51 drill string.

Fuel consumption cut in half


Field studies show that the FlexiROC T45 with
folding boom, depending upon rock conditions,
uses only half as much fuel as its predecessor the
ROC F9 using the same rock drill. Additionally, the
new rock drill COP 3060 mounted on a fix boom and
aluminum feed, manages large diameters using
the T60 drill string with outstanding performance
and reliability.
-Its an incredible accomplishment to increase
productivity and drilling capacity while reducing
fuel consumption so dramatically. Everybody wins
when theres less environmental impact, a better
working environment, and higher profitability,
explains Mario Santillan, Product Manager at
Atlas Copco Surface Drilling Equipment.

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FlexiROC T45 with fix boom and the new COP
3060 rock drill and T60 drill string.

Innovative solutions
Key to the success of the new rig lies in building
on a proven platform fitted with a number of clever
solutions to effectively reduce unnecessary energy
losses and increase productivity. During operation, the
operator can adjust the airflow and the dust collector
fan speed according to actual working demands. The
speed of the engine and compressor are then adjusted
automatically.
The FlexiROC T45 - with its efficiency, productivity,
and superior cabin environment - is everything you
would expect from Atlas Copco. However, these are
not the only proofs that Atlas Copco is on the leading
edge of drilling development. Compared to similar rigs
on the market the FlexiROC T45 has 50% fewer hoses
and 70% fewer couplings.

Sustaining the environment


-Because hydraulic functions and electrical
components are positioned in close proximity to their
functions, components are easier to service and
maintain and the risk of leakage is greatly reduced,
explains Dieter Koss, Business Line Manager Drilling
Equipment, Atlas Copco MCT GmbH who further adds:
-The hydraulic tank is almost 60% smaller than
on previous generations, making it possible to use
biological hydraulic oil without increasing total costs.
Should an accident occur, no costly environmental
cleanup is needed, simply rinse with water.

Compared to similar rigs on the market the


FlexiROC T45 has 50% fewer hoses and 70%
fewer couplings.

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FOR MORE INFORMATION AND CONTACT:
Atlas Copco MCT GmbH , Surface Drilling Equipment
Business Line Manager, Dieter Koss
Tel.: +49 (0) 201 2177 273 | Mobil: +49 (0) 173 7077 273
eMail: dieter.koss@de.atlascopco.com
Internet: www.atlascopco.com
Product Manager, Mario Santillan
Tel.: +46 19 670 70 00 | Mobil: +46 (0)70 811 82 93
eMail: mario.santillan@se.atlascopco.com
Internet: www.atlascopco.com
Communications Professional, Sandra Lee
Tel.: +46 (0)19 503 1240 | Mobil: +46 (0)73 337 80 28
eMail: sandra.lee@se.atlascopco.com
Internet: www.atlascopco.com
The new COP 3060 rock drill
and T60 drill string.

The FlexiROC T45 is equipped with an


engine that meets the new and more stringent
environmental demands according to Tier
4. This means that sulfuric oxide has been
reduced by 50% and particle emissions by
an outstanding 90%. A Tier 3 engine is also
offered.

The innovative solutions in this new surface drill


rig, FlexiROC T45, for quarrying and mining, makes it
not only a very fuel efficient drill rig in its hole range
on the market but also very productive.

Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment systems, construction and mining
equipment, power tools and assembly systems. With innovative products and services, Atlas Copco delivers solutions for sustainable productivity.
The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2011, Atlas Copco
had 37 500 employees and revenues of BSEK 81(BEUR 9).
Atlas Copco Surface Drilling Equipment is a division within Atlas Copcos Construction and Mining Technique business area. It develops,
manufactures, and markets rock drilling equipment and mobile crushers and screeners for various applications in civil engineering, quarries and
open pit mines worldwide. The division focuses strongly on innovative product design and aftermarket support systems, which give added customer
value. The divisional headquarters and main production center is in rebro, Sweden. More information is available on www.atlascopco.com

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ThyssenKrupp Steel Europe

ThyssenKrupp Steel Europe:

expands its service network on four continents!


o offer more and better services to its customers in the construction industry and the minerals &
T
mining sector worldwide, ThyssenKrupp Steel Europe is expanding its heavy plate distribution
network, with new service centers on four continents. Alongside wear-resistant and high-strength
special structural steels such as XAR, XABO, N-A-XTRA and PERFORM, ThyssenKrupp Steel
Europe now also offers complete components and repair solutions.
With the growth of many countries in Latin America,
Asia and Africa, global demand for raw materials is
rising. For the mining and transportation of raw materials
and the expansion of the infrastructure in these regions,
special structural steels from ThyssenKrupp Steel Europe
open up a number of interesting opportunities. To be able
to deal even more individually with the requirements
of its customers in booming regions, ThyssenKrupp
Steel Europe is now broadening its sales strategy. For
the future we are looking beyond the sale of a single
plate, extending our value chain and expanding our
distribution network to improve availability and increase
our processing capabilities on four continents, says
head of sales Peter Selbach. As a result ThyssenKrupp
Steel Europe will be offering companies in the minerals
& mining industry and the construction sector an even
wider range of services in the future. Tailored processing
solutions will round off the portfolio.

For the mining and transportation of raw materials and the


expansion of the infrastructure worldwide, special structural steels
from ThyssenKrupp Steel Europe open up a number of interesting
opportunities. To be able to deal even more individually with the
requirements of its customers in booming regions such as Latin America,
Asia and Africa, ThyssenKrupp Steel Europe is now broadening its
sales strategy. Alongside wear-resistant and high-strength special
structural steels, the steel company now offers complete components
and repair solutions.

The global network of ThyssenKrupp Steel Europes


Heavy Plate operating unit consists of the companys
own service centers, joint ventures and exclusive
partnerships at the most important high-growth
business locations. For example the Chilean subsidiary
ThyssenKrupp Aceros y Servicios has been supporting
the booming minerals & mining industry in Latin America
for 50 years. Specialist processing operations serve
customers including mining companies and their
suppliers in Chile and Colombia. In the future the
heavy plate experts will also be using the expertise they
have acquired in South America in Asia: ThyssenKrupp
recently opened a warehouse in Taiwan to supply the
Southeast Asian market.
To find out more about ThyssenKrupp Steel Europes
products and capabilities in special structural steels,
visit us at bauma at the Munich Exhibition Center, hall
A6, booth 429, from April 15 to 21, 2013.
ThyssenKrupp AG, Corporate Communications
Erik Walner
Phone: +49 203 52 45130 | Telefax: +49 203 52 25707
eMail: erik.walner@thyssenkrupp.com
www.thyssenkrupp-steel-europe.com

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ThyssenKrupp Steel Europe

ThyssenKrupp Steel Europe

When the going gets tough:


XAR heavy plate for mining machinery!

XAR: The special structural steel XAR from ThyssenKrupp Steel Europe is a match for the highest wear requirements, for
example in dump trucks. That makes it easy to transport raw materials around the world. The robust, hard-wearing XAR steels are
ideal for use in, for example, mining equipment, cement plants, and earth-moving and agricultural machinery.

hroughout the world, XAR special structural steels from ThyssenKrupp Steel Europe make the mining,
T
transportation and processing of raw materials easier. Deep rock, fluctuating climatic conditions and extreme
loads are no problem for the robust XAR (eXtra Abrasion Resistant) steels from ThyssenKrupp Steel Europe.
They were developed especially for applications requiring maximum wear resistance for example in mining
equipment, cement plants, and earth-moving and agricultural machinery.
In the minerals & mining sector worldwide they have
long been a by-word for reliability. Customers in Europe,
Asia and North and South America purchase XAR steels
via ThyssenKrupp Steel Europes global network. Only
recently the steel company opened a warehouse in Taiwan
especially to distribute XAR heavy plate.
With plate thicknesses of 3 to 100 millimeters, XAR
steels offer optimum solutions for all areas of mining
equipment. Alloyed with chromium and niobium, they
display hardnesses of up to 600 Brinell, guaranteeing
optimum wear resistance. Components made from XAR
steels last five times longer than conventional structural
steel components. XAR steels also meet the highest
requirements in terms of quality and processing properties.
They are ideal for press braking, bending, welding and
cutting. In addition, with thickness tolerances as low
as 0.2 millimeters, XAR heavy plate can help reduce
weight.

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With the spectrum of grades ranging from XAR 300 to


XAR 600, steel solutions can be tailored to requirements:
XAR 400 is the most commonly used variant. It is suitable
for example for screening and crushing machinery. For
components subject to less extreme loads for instance in
conveying troughs in mining XAR 300 is recommended.
This steel combines optimum surface quality with
outstanding cost-effectiveness. XAR 600 offers the
highest wear resistance for use for example in heavy
dump trucks. For applications in excavating and earthmoving machinery where the going is particularly tough,
XAR HT (High Toughness) is the material of choice.
To find out which material best meets your requirements,
visit us at bauma, hall A6, booth 429, from April 15 to 21.


ThyssenKrupp AG, Corporate Communications
Erik Walner
Phone: +49 203 52 45130 | Telefax: +49 203 52 25707
eMail: erik.walner@thyssenkrupp.com
www.thyssenkrupp-steel-europe.com

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PHOENIX Conveyor Belt Systems

PHOENIX at BAUma:

PHOENIX with New Monitoring System and


Corrugated Sidewall Belt
PHOENOGUARD
PX
revolutionizes
conveyor belt monitoring PHOENIX
S-Wall negotiates inclines of up to
90 degrees
Hamburg, 2013. Minimizing maintenance costs
and ensuring the adaptability of record-setting
conveyor belt systems are benchmarks that
PHOENIX Conveyor Belt Systems has been setting
itself for many years. The technology specialist will
showcase impressive and clear examples of its
innovative art of engineering with its cutting-edge
conveyor belt concepts and captivating high-tech
solutions at bauma 2013 (hall C2, booth 212)..

The Independent PHOENOGUARD


PX Localizes Any Damage
PHOENIX Conveyor Belt Systems is introducing
a
revolutionary
new
development
with
PHOENOGUARD PX. The autarchical monitoring
system continuously measures the current
overall condition of the conveyor belt, internally
and externally. From notching on the covers to
penetration of foreign bodies and damaged steel
cords, this unprecedented technology not only
records damage but also intervenes automatically in
the operation of the system in cases of emergency.
If the system identifies damage that could result in
breakdown of the conveyor belt, PHOENOGUARD
PX immediately shuts the conveyor system down. In
the case of minor damage that has no direct impact
on the condition of the conveyor belt, the system
triggers an alarm. Users can adjust these settings in
line with their requirements. PHOENOGUARD PX
uses this method of targeted intervention to prevent
serious damage from occurring and dramatically
reduce maintenance costs. If users want to get an
impression of the overall condition of the conveyor
belt, the system is able to provide a comprehensive
snapshot image at the click of a mouse..

Issue 01 | 2013

PHOENOGUARD PX ist in der Lage, eine umfassende


Momentaufnahme per Mausklick zu liefern. / PHOENOGUARD
PX is able to provide a comprehensive snapshot image at the
click of a mouse.

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Introducing Steep-angle Conveyor
Belting To Our Range
On show will be the range of PHOENIX S-Wall
corrugated sidewall belts. These steep-angle and vertical
conveyor belts are the latest state of the art products to be
added to the PHOENIX product range. Advantages of this
system are that it eliminates the need for transfer points
which in turn helps to minimize spillage. The system also
allows for the maximum utilization of space, especially
where this is at a premium. PHOENIX has expanded on the
conventional cold-bonding manufacturing technique, to
now include Hot Vulcanisation.
This method uses heat and pressure to vulcanise
the side-walls and cleats to the base-belt, leading to
exceptional adhesion levels. This allows the belts to be
used in both higher temperature and particulally stressfull
applications. This durable and resilient bonding method
noticeably increases the service life of the belt whilst
reducing maintanence costs in special applications.

PHOENIX Displays Record Book


Visitors will also gain an insight into the tremendous
potential of the many solutions offered by PHOENIX at
bauma: The worlds strongest conveyor belt, belts with
the highest conveying capacity PHOENIX technology is
what lies behind these records and many other extreme
conveyor belt solutions. Across the globe, the customized
conveyor belts transport goods under the most complex
of requirements and, in doing so, set some spectacular
records. The new Extreme Conveyor Belt Solutions
brochure gives a fascinating insight into the virtually
boundless possibilities and the tremendous performance
capability of PHOENIX conveyor belts. Illustrative examples
demonstrate the impressive and customized way in which
PHOENIX products convey material.

Gezeigt wird das Spektrum der PHOENIX


S-Wall Wellenkantengurte / On show will be the range of
PHOENIX S-Wall corrugated sidewall belts.

About PHOENIX
PHOENIX Conveyor Belts, headquartered in
German Hamburg, is an international group company
that is more than 150 years old. Phoenix Conveyor
Belt Systems GmbH has produced significant
advancements in conveyor belt design, which
include world records such as the strongest belts,
the steepest overland and the worlds heaviest belt,
to name a few.
Phoenix serves the worldwide bulk handling
industry from international production facilities with
textile and steel cord conveyor belts. Technological
achievements such as the PHOENOTEC active belt
protection system in combination with more than
100 years of experience in conveyor belt production
make PHOENIX Conveyor Belts the first choice for
highest reliability and efficiency.

FOR MORE INFORMATION AND CONTACT:


Phoenix Conveyor Belt Systems GmbH
Bernd Ksel
Hannoversche Strae 88
D-21079 Hamburg
Phone 040 7667 2205
Specialised Belting Solutions Ltd.
Fax 040 7667 2411
Tom Webster
eMail: bernd.kuesel@phoenix-cbs.com
Unit 26-32 Brunel Way
Internet: www.phoenix-cbs.com
Thetford, Norfolk, UK, IP24 1HZ
Phone +44 (0) 1842 754392
Fax +44 (0) 1842 765264
eMail: tom.webster@phoenix-cbs.com
Internet: www.sbsbelting.com

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Machines and systems for bulk material


and piece good transport:

BEUMER Group GmbH & Co. KG


Beckum | Germany

BEUMER provides efficient solutions for the cement industry

he BEUMER Group, headquartered in Beckum


and with several companies around the world,
develops and realises system solutions that provide
increased efficiency in the cement and building
material industry. The company can build on more
than 75 years of international experience in this
field. With the integration of Enexco Teknologies of
India, the BEUMER Group strengthened its presence
in the cement industry in one of the most important
future markets.
Our goal is not the short term profit, but the long term
success - this is the guiding principle of the BEUMER
Group, which was founded by Bernhard Beumer
in Beckum in 1935. Family spirit, the integration of
employees into all operational processes, innovation,
communication and the constant dialogue between
Sales, Engineering and Research and Development
are the basis for this future-oriented alignment.
Manageable growth, global market presence and
a large range of products in the conveying, loading,
palletising, packaging segments - as well as sortation
and distribution technology - ensure the long-term
success of the company. The BEUMER Group employs
about 3,200 people and achieves an annual turnover of
about 500 million EUR.

The BEUMER Group is an international leader in the


manufacture of intralogistics for conveying, loading,
palletising, packaging, sortation and distribution technology.

The BEUMER belt bucket elevators impress by durability and their


considerable conveying heights, which depend on the project.

The system supplier designs, constructs and


installs systems tailored in detail to the specific
project requirements, and with its belt conveyors
provides economic and sustainable solutions. Today
the BEUMER Group ranks among the worlds leading
technology providers for curved belt conveying
systems, either as troughed belt conveyors with open
design or as Pipe Conveyor with closed design. They
can be adapted optimally to the environment and can
negotiate long distances and large differences in
height. This is ensured by their optimal routing through
the terrain as well as by the narrow horizontal and
vertical curves which can even overlap. Therefore
rugged terrain, rivers, streets, buildings or train tracks
do not present obstacles. Furthermore, the BEUMER
Group supplies high-capacity belt bucket elevators

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NEWS & REPORTS


provided with centre distances up to 200 metres and
high-quality steel wire belts, endless closing and
special bucket mountings. This way the BEUMER Group
enables higher conveying capacity and longer service
life. In addition, belt apron conveyors for hot materials
also are supplied.
In order to palletise load units in the building material
industry, the BEUMER Group provides effective solutions
with the BEUMER robotpac robotic palletiser and
the BEUMER paletpac layer palletisers. Bags filled
with bulk material are stacked layer by layer with high
geometric accuracy and stability and these stacks can
be easily conveyed into the BEUMER stretch hood
high-capacity packaging system arranged behind
the palletiser. Packaging load units with the BEUMER

stretch hood is quick, safe and sustainable, and has


been dimensioned for many different film thicknesses.
It impresses with high throughput and reliable film
handling.
The BEUMER Group offers comprehensive service for
all product lines - from maintenance, troubleshooting,
repair and spare parts to system modernisation and
expansions. In developing its solutions, the target
of the Group is always to provide for and preserve
sustainability. To this end, the Group developed a
validation system, the BEUMER Sustainability Index
(BSI), which is used to evaluate the sustainability of its
technologies in a continuous, systematic and verifiable
way.

The BEUMER Group is known for outstanding and extensive know-how in


the field of belt conveying systems.

About BEUMER Group


The BEUMER Group is an international leader
in the manufacture of intralogistics systems
for conveying, loading, palletising, packaging,
sortation and distribution technology. Together
with Crisplant a/s and Enexco Teknologies India
Limited, the BEUMER Group employs about 3,200
people and achieves an annual turnover of about
500 million EUR. With its subsidiaries and sales
agencies, the BEUMER Group is present in many
industries the world over. For further information
visit www.beumergroup.com.

FOR MORE INFORMATION AND CONTACT:


BEUMER Group GmbH & Co. KG
Oelder Str. 40
59269 Beckum | Germany
Internet: www.beumergroup.com

Regina Schnathmann
Tel. + 49 (0) 2521 24 381
Regina.Schnathmann@beumergroup.com
Verena Breuer
Tel. + 49 (0) 2521 24 317
Verena.Breuer@beumergroup.com

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BHS-Sonthofen

Rotor impact mills for sand processing :

BHS-Sonthofen: Cubical shaped grains


with round edges
At BAUMA 2013, BHS-Sonthofen is showcasing its unique rotor impact mills,
which are not manufactured by any other company in the world. They produce
crushed sand with special characteristics that cannot be achieved in the same
quality with any other machine: the grains are cubical, but their edges are
rounded. Dry mortar produced with this type of sand is easier to use and makes
concrete easier to pump.

Unique process increasingly being


used for other applications
Last year BHS-Sonthofen delivered numerous RPMtype rotor impact mills for new dry mortar factories
in fast-growing Asia and the Middle East, further
consolidating its position as market leader in machinery
for producing dry mortar sands. BHS rotor impact mills
employ a globally unique principle.

These rotor impact mills are increasingly being used


for other applications than manufacturing sand for
the dry mortar industry; for instance, they are being
employed more and more frequently to make sand for
ready-mixed concrete, as the concrete containing such
sand has excellent pumping properties. Around the
world, the number of rotor impact mills is also growing
in the asphalt industry, in the manufacture of surfaces
for sports facilities, as well as for grinding limestone,
dolomite, gypsum, anhydrite and quick lime.

Rotor impact mill, type RPM 1513 for


throughput up to 75 t/h.

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The hammers are wearing parts and can
easily be replaced in just a few simple steps.

The rock breaks upon impact and assumes its cubical


form. Repelled by the anvil ring, which is available in
toothed and smooth versions, the material hits the
hammers again, is further crushed, and thrown back
against the anvil ring. This repeats until the material is
small enough to pass through the gap between the rotor
and the anvil ring, and falls out through two discharge
chutes.

When it comes to crushing rocks, the rotor impact mill


works best on slightly to moderately abrasive material.
It can process feed sizes up to 56 mm. Larger feed sizes
can be used for materials that are easy to crush, such
as quick lime. Throughput can reach 75 t/h.
The horseshoe-shaped hammers in BHS rotor impact
mills are also absolutely unrivaled. The input material is
fed into the machine from above through the centrallylocated feed tube. When it hits the rotor, it is accelerated
outward at high speed by the centrifugal forces, where
it is then caught by the horseshoe-shaped hammers,
which impel it against the anvil ring of the annular
housing.

The multi-phase crushing process serves to grind the


edges of the particles, closely approximating the way
sand is produced in nature. In practical applications,
the rounded grain form makes it easier to process the
material. For example, plaster made from this sand is
easier to spread than if made from sand with sharp
edges. The same effect makes the rotor impact mill an
attractive choice for producing sand for ready-mixed
concrete, which is then easier to pump.

The particles are caught and crushed between


the rotating hammers and the anvil ring.

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About BHS-Sonthofen
BHS-Sonthofen GmbH offers innovative and efficient
mechanical process solutions for mixing, crushing, recycling
and filtration applications. The company focuses on developing
and manufacturing plants capable of operating efficiently for
long periods, even under challenging conditions.
We have been working in the crushing technology sector
for more than 100 years, manufacturing crushing machines
that are used for processing minerals in quarries and gravel
pits and in the mining industry. Our products include state-ofthe-art impact crushers and mills with horizontal and vertical
shafts. For more information, visit www.bhs-sonthofen.de.

FOR MORE INFORMATION AND CONTACT:


Layout of the rotor impact mill with anvil ring and open inlet
cover .

The sand produced has a high proportion of


grains sized between 0 and 2 mm. Compared to
conventional impact mills, the rotor impact mill
results in a considerably higher proportion of useful
grains.

BHS-Sonthofen GmbH
Roland Schmid
Head of Marketing & Communications
An der Eisenschmelze 47
D-87527 Sonthofen
Tel. +49 8321 6099-231
Fax +49 8321 6099-220
eMail: press@bhs-sonthofen.de
Internet: www.bhs-sonthofen.de

The gap between the horseshoe hammers and the


anvil ring is adjustable and the peripheral speed of
the rotor is variable, making the BHS rotor impact mill
flexible for use in a wide range of applications. It also
effectively processes fine off-spec gravel fractions,
making it an efficient and future-proof solution.
The adjustable hammers can be installed and set
manually without any special tools or lifting devices.
They ensure the output grain-size curve of the BHS
rotor impact mill remains constant over the entire
service life of the wearing parts, maintaining a
consistent quality of the final product.
The entire inlet cover can be pivoted for optimum
accessibility, which greatly simplifies maintenance
of the machine.

The crushing chamber of the rotor impact mill


features horseshoe-shaped hammers.

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NEWS & REPORTS


BHS-Sonthofen

Processing technology :

BHS-Sonthofen: Gravel processing with


BHS rotor centrifugal crushers
At BAUMA, BHS-Sonthofen demonstrates the rotor centrifugal crushers of the
RSMX series for processing hard and medium-hard rock to produce aggregate
chippings and high-quality aggregates. The rock-on-rock principle and the
patented rotor with just two centrifugal chambers offer considerable advantages
over multi-chamber rotors in everyday practice.

Wear is virtually a thing of the past


The requirements on the building materials concrete
and asphalt and thus on the gravel, chippings and
sand used for their production have continuously risen
in recent years. Since demand for high-grade crushed
sand and high-quality aggregates is also constantly
rising, gravel and aggregate plants have to expand and
equip their machine pools in order to meet the European
standards and directives that require increased use of
high-quality aggregates. BHS offers machines in four
different sizes for throughput rates of up to 400 t/h.

Crushing with BHS impact crushers with vertical


shafts and twin-chamber rotors is a popular choice
in many plants for the production of high-quality
aggregates.
BHS rotor centrifugal crushers adopt the impact
crushing principle: the material is fed vertically from
above onto the high-speed rotor, which is mounted
on a shaft with vertical bearings. In both chambers
of the rotor, the input material is rapidly accelerated
outwards due to the high circumferential speed,
routed out via a naturally forming material bed and
hurled at high speed against a fixed annular wall,
generally consisting of an anvil ring made of heavyduty casting or an autogenous material bed.

BHS rotor centrifugal crusher of type RSMX for production of highgrade crushed sand, aggregate chippings and high-quality aggregates.

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Crushing function of the BHS rotor


centrifugal crusher with anvil ring by means
of the impact crushing principle.

The rotors patented by BHS with just two centrifugal


chambers offer considerable advantages over threechamber and multi-chamber rotors:




maximum input grain sizes of up to about 80 mm


for hard rock and up to 150 mm for soft rock
optimal material flow in the rotor, free from
clogging
15 to 20 percent greater throughput rate with
the same power consumption
wear-related costs reduced by up to 25 percent
exhaust air quantity reduced by more than 10
percent.

Choice of rock shelf or anvil ring


The rotor centrifugal crushers from BHS can optionally
be operated with an anvil ring made of heavy-duty
casting or with a rock shelf, and can thus be variably
adapted to a wide range of different requirements.
If the anvil ring is used, the input material is crushed
intensively by the hard impact of the rock against the
impact wall, thereby developing the crushed face count
of the chippings. Previously damaged rock and friable
components are destroyed, significantly improving the
test results of the final products. The stepped shape of
the anvil ring causes the crushed material to be removed
immediately from the crushing chamber without further
abrasion.

Crushing function of the BHS rotor


centrifugal crusher with rock shelf by means
of the rock-on-rock principle.

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NEWS & REPORTS


BHS rotor centrifugal crusher of
type RSMX with anvil ring.

BHS rotor centrifugal crusher of


type RSMX with rock shelf.

If the rotor centrifugal crusher is operated with a


rock shelf, it is also suitable for highly abrasive input
materials, such as quartz, as the rock-on-rock
principle means that only very few machine components
are subjected to wear.
Another advantage is that, unlike in other crushing
systems, the condition of the wearing parts has no
effect on the grading curve: it is only the speed of the
rotor that determines the crushing performance.
Depending on the application specified by the
customer and the properties of the rock, operation of
the rotor centrifugal crusher can be varied:

Issue 01 | 2013

BHS-Sonthofen
at BAUMA in Munich,
April 15 to 21, 2013:
Hall B2, booth 325/420

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NEWS & REPORTS


with anvil ring:
as crusher and cubicator for the
production of aggregate chippings and
high-quality aggregates from soft and
medium-hard rock
for production of crushed sand
with rock shelf:
as crusher and cubicator for the
production of aggregate chippings and
high-quality aggregates from hard rock
with rock shelf or anvil ring (depending on
the application):
for selective crushing of friable rock
while maintaining the hard core of the
material
for disaggregation of conglomerates

About BHS-Sonthofen
BHS-Sonthofen GmbH offers innovative and efficient
mechanical process solutions for mixing, crushing, recycling
and filtration applications.
For more than 100 years, the crushing technology division
of BHS has been manufacturing machines that are used for
processing minerals in quarries and gravel pits and in the
mining industry. The product range includes impact crushers
and impact mills with horizontal and vertical shafts. For more
information, visit www.bhs-sonthofen.de.

Every kind of rock has different characteristics;


for this reason, BHS conducts tests at its in-house
technical center on request. These tests are carried
out using original industrial scale machines to ensure
optimal and realistic crushing results. These tests
give the customer the certainty that his outlay is well
invested and that the new plant is future-proof.

FOR MORE INFORMATION AND CONTACT:


BHS-Sonthofen GmbH
Roland Schmid
Head of Marketing & Communications
An der Eisenschmelze 47
D-87527 Sonthofen
Tel. +49 8321 6099-231
Fax +49 8321 6099-220
eMail: press@bhs-sonthofen.de
Internet: www.bhs-sonthofen.de

BHS rotor centrifugal crusher of type RSMX with


the patented twin-chamber rotor, vertical shaft and
anvil ring.

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NEWS & REPORTS


HAVER NIAGARA GmbH

HAVER NIAGARA GmbH Member of the new HAVER &


TYLER Alliance:
HAVER & BOECKER Machinery Division Muenster became
HAVER NIAGARA GmbH

HAVER NIAGARA GmbH is a processing specialist in the


machine construction and engineering industry for primary
and secondary raw materials of the mining, recycling and
building materials industries, its main areas of activity
being screening, washing, and pelletising.
HAVER NIAGARA GmbH was founded on January 1,
2012, and made an independent PLC after over 80 years
as part of HAVER & BOECKER OHG. This step was taken
to effect a separation between HAVER & BOECKER OHGs
two main business sectors, namely packaging technology
and processing technology, and to allow each section to
concentrate on their core areas of competence. Graduate
engineer Mr Peter Grotjohann has been appointed CEO of
HAVER NIAGARA GmbH. The Sales and Field Service team
customers are familiar with will continue to act as contacts
and advisors on all processing technology matters.
HAVER NIAGARA GmbH looks back on many years of
experience in processing technology, all of which began
with the construction of the first NIAGARA vibrating screen
in 1930. HAVER NIAGARA GmbHs key fields of activity now
lie in screening, washing, pelletising and in the engineering
of plants and systems for the extractive industry. Its target
markets are Europe, Asia, Africa and Australia.
HAVER NIAGARA belongs to the renowned HAVER
Group and is a member of the HAVER & TYLER Alliance.
The HAVER & TYLER Alliance, formerly known as THE
HAVER SCREENING GROUP, sees itself as an amalgamation
of all the processing specialists that belong to the HAVER
Group. This includes not only HAVER NIAGARA GmbH but
also HAVER & BOECKER Latinoamericana in Brazil and
W.S. Tyler in Canada.
The new HAVER NIAGARA GmbH signet perfectly
illustrates the global orientation of the processing
technology alliance. The signet outline matches that of
the HAVER & BOECKER logo with a stylised globe and the
hammer and chisel mining symbol. The letters H and
T stand for the HAVER-Group in general and specifically
for the companies HAVER & BOECKER and W.S. TYLER
Canada.

Issue 01 | 2013

The new trade marks of


HAVER NIAGARA GmbH

The name HAVER NIAGARA expresses the pride of 70


employees and managers in the history of their traditional
company and is a reference to both the HAVER Group and
the Niagara Falls in North America, close to which the first
NIAGARA eccentric vibration screen in the world was
invented and manufactured.
Traditional NIAGARAtrade mark showing the
world-famous
Niagara
Falls

The HAVER & TYLER Alliance and its sales network


provide outstanding quality in processing technology,
innovation, customer proximity and service on all
continents.
The highlights on show at bauma 2013 are the new
F-Class screening machine, the Hydro-Clean 2000 highpressure washer and the HAVER-Snap-Guard wear
protection system.
Further information is available on the www.haverniagara.
com and www.havertyler.com websites.

FOR MORE INFORMATION AND CONTACT:


HAVER NIAGARA GmbH, Mnster
Dipl.-Geol. THOMAS HOLZLEHNER
Marketing and Public Relations
Robert-Bosch-Strae 6 | D-48153 Mnster
Tel. +49 251 9793-102
Fax: +49 251 9793-156

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NEWS & REPORTS


HAVER NIAGARA GmbH

HAVER NIAGARA F-Class Eccentric Screening


Machine with New Bearing Concept:

Buffering of outer bearings reduces risk of bearing failure


For the first time at bauma 2013 in hall B2, stand 129/236,
the HAVER & TYLER Alliance will be exhibiting the new,
patent-pending bearings concept in the F-Class eccentric
screen series which will introduce a further innovation
to processing technology. This new development was
masterminded by HAVER & TYLER Alliances Innovation
Management Department.

radial vibration is transferred directly to the outer bearings


and support frame. This bears the risk of direct or mediumterm damage to the bearings. Buffering the outer bearings
helps to extend the service life of the bearings with radial
vibration and increase the availability of the screening
machine during operation. Investing in our innovative
bearings concept with the outer bearings encased in
rubber has a positive effect on your ROI.

The concept has floating outer bearings embedded in


rubber which buffer radial vibrations from the eccentric
drive shaft. Vibrations such as these occur with strong
load alteration when the screening machine feed rate
suddenly rises during operation or when external force is
applied, such as the direct impact of a hydraulic hammer
used to remove blockages in a primary crushing plant or by
excavator shovels in mobile plants. In standard eccentric
vibration screens the outer bearings are not buffered and

The new HAVER NIAGARA F-Class has all the


constructive and functional properties of the familiar
HAVER NIAGARA T-Class. The modular, standardised
assembly of the components, comprising the screen box,
continuous drive train, spring brackets and support frame,
simplifies maintenance and spare parts storage. Its wide
range of operation, i.e. the various combinations of drive
shaft speed and amplitude from 630 to 1,060 rpm and 3.1 to

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NEWS & REPORTS


9 mm, enable the eccentric vibration screen to be perfectly
adapted to suit all tasks and requirements. The optional
reinforced screen box frame has been designed for heavyduty use or comes into play when higher demands are made
of machine availability, such as in the mining industry. With
a machine width of up to 3,000 mm the HAVER NIAGARA
F-Class is extremely suitable for high feed and throughput
rates. The inner and outer bearing size combinations
of 150/110 mm, 180/130 mm and 220/150 mm are geared
towards oversized outer bearings to ensure availability
even with large loads.
The HAVER NIAGARA F-Class eccentric vibration screen
is fully balanced, i.e. the dynamic loads during screening
machine operation are minimal, so that the static loads of
the machine and feed material are determinative when
dimensioning the steel structure.
The HAVER NIAGARA F-Class is distinguished by the
fact that various screening media can be combined with
one another on one deck. Depending on the task on hand,
screen meshes, pressure-welded gratings, snap-in screen
panels or perforated plates can be combined. Adapters
enable screening media from different manufacturers to
be used; the screen operator is therefore not committed to
any particular manufacturer. Subsequent modifications to
the assigned media are also not a problem as the HAVER
mounting rail system is not welded to the screen box
crossbeam.

At bauma 2013 a double deck HAVER NIAGARA F-Class


S 180/130 2400 x 6000 2D will be on show which has been
designed exemplarily for armourstone screening and a
feed grain of 0/450 mm. The screen deck sizes are 2,400 x
6,000 mm. The upper deck is fitted with perforated plates
with 100-mm openings. The lower deck has variable
configurations which can cope with various screening
tasks.
The combination on display, consisting of ISENMANN
PU snap-in screen panels, TY wire and FlexMat modules,
all of which are fixed down using the ISENMANN WS85
hold-down system, guarantee optimum stability, an open
screening surface, selectivity and blockage-free operation
in each phase of the screening process.
The HAVER-Snap-Guard wear protection system
protects the crossbeams from wear.

FOR MORE INFORMATION AND CONTACT:


HAVER NIAGARA GmbH, Mnster
Dipl.-Geol. THOMAS HOLZLEHNER
Marketing and Public Relations
Robert-Bosch-Strae 6 | D-48153 Mnster
Tel. +49 251 9793-102
Fax: +49 251 9793-156

The crossbeams in the screen box can also be


optionally fitted with the patented HAVER-Snap-Guard
wear protection system that permits wear protectors to be
quickly and easily replaced during machine servicing.
The HAVER NIAGARA F-Class eccentric
screen is suitable for all classifying jobs
from medium to large grain size where
load independent screening is necessary
due to fluctuating feed rates and clinging
feed material.

HAVER NIAGARA F-Class Exzentersieb


mit gepufferten Auenlagern

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HAVER NIAGARA GmbH

HAVER NIAGARA Hydro-Clean 2000 New High


Pressure Washing System with Increased Material
Throughput: Minimized water consumption and
improved cleanliness of bulk mineral products

The HAVER & TYLER Alliance will be introducing the


HAVER NIAGARA Hydro-Clean 2000 under the aegis of
HAVER NIAGARA GmbH. The HAVER NIAGARA HydroClean 2000 is the result of consistent further development
of the well-known Hydro-Clean high-pressure cleaning
system which has proved its cleaning power, high
throughput rates, availability, economic efficiency and
ease of maintenance in many different areas of application
worldwide.
The tried-and-tested modular system has been retained;
new features include two adjacent washing rotors within
one washing drum. The result is a high material throughput
of up to 400 metric t/h and improved cleaning of clinging
dirt from the 0/150 mm target grain size.
As with all other sizes of HAVER NIAGARA Hydro-Clean
only high-pressure jets are used for cleaning, these being
directed at the raw material by rotor nozzles at pressures
of up to 150 bar. As the jets of water rotate with the washing
rotor the raw material is thoroughly ploughed through.
Material is cleaned merely by the impact of the stream
of water and the shearing processes in the raw material
bed.
Without exception all moving machine components
are outside the flow of material. This makes the HAVER
NIAGARA Hydro-Clean high-pressure washer a cleaning
system with minimum wear.
The machines low water consumption of 0.10.2 m/t
protects our natural resources and qualifies the HAVER
NIAGARA Hydro-Clean for use in areas with a limited
supply of water. It also creates a process that has a low
water circulation, thus cutting operating costs.
Its modular and compact design, installed total power
requirement of 230 kW maximum and total weight of below
6,000 kg allow the HAVER NIAGARA Hydro-Clean 2000 to
be used as a stationary, partially or fully mobile system or
as a plant component.

Issue 01 | 2013

HAVER NIAGARA Hydro-Clean 2000 with two wash rotors in one


single washing drum

The HAVER NIAGARA Hydro-Clean is available in four


sizes: the Hydro-Clean 350, Hydro-Clean 700, Hydro-Clean
1000 and Hydro-Clean 2000. Its areas of application include
mining, exploration, recycling, the quarrying of sand and
gravel as building materials and quarrying stone and
earth.
.

FOR MORE INFORMATION AND CONTACT:


HAVER NIAGARA GmbH, Mnster
Dipl.-Geol. THOMAS HOLZLEHNER
Marketing and Public Relations
Robert-Bosch-Strae 6 | D-48153 Mnster
Tel. +49 251 9793-102
Fax: +49 251 9793-156

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NEWS & REPORTS


HAVER NIAGARA GmbH

HAVER-Snap-Guard Optimized Wear Protection


for Screening Machines Crossbeams:

Easy maintenance and high efficiency

HAVER-Snap-Guard crossbeam wear protection

The HAVER & TYLER Alliance is introducing the patented


HAVER-Snap-Guard crossbeam wear protection system
under the aegis of HAVER NIAGARA GmbH. This unique
system has been developed to improve wear protection and
minimise maintenance times. As opposed to the standard
method of gluing wear protection to the crossbeams and
laboriously removing the remains thereof once worn, in
combination with the HAVER mounting rail system the
HAVER-Snap-Guard is simply clamped and snapped
onto the crossbeam.
The HAVER-Snap-Guard is fitted and removed by hand
without the need for any tools. HAVER-Snap-Guard wear
protection components are standardised and designed to
fit the HAVER mounting rail system.

Issue 01 | 2013

The components are made of moulded PU parts which


are used to cover the threaded rods on the mounting rail
clamps and exposed crossbeam sections, thus protecting
them from abrasion by the feed material.

FOR MORE INFORMATION AND CONTACT:


HAVER NIAGARA GmbH, Mnster
Dipl.-Geol. THOMAS HOLZLEHNER
Marketing and Public Relations
Robert-Bosch-Strae 6 | D-48153 Mnster
Tel. +49 251 9793-102
Fax: +49 251 9793-156

www.advanced-mining.com

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NEWS & REPORTS


New Holland Construction

New Holland Construction will launch new W170C


Recycler wheel loader at Bauma 2013

New Holland: W170C Recycler

New Holland builds on the success of its W170C wheel


loader in the Recycling industry, due in great part to its
exceptionally low fuel consumption as low as 10 litres/
hour and best-in-class bucket payload, by launching a new
version specially designed for the very tough, aggressive
and dusty working conditions typical of waste handling
and recycling facilities.

Advantages of the W170C:








New Heavy Duty cooling box designed for extra


efficient cleaning
Full package of protections for extra operator
safety and machine durability
More power, less fuel consumption and more
uptime with SCR Tier 4 interim solution
More safety indoors with SCR that stops sparks
More pushing power and faster cycles with
Ecoshift
More grip and less wear with the Heavy Duty axles
with open differentials and 100% diff lock
More fuel economy with ECO Mode and ECOSTOP

Issue 01 | 2013

New Heavy Duty cooling box copes with


the most extreme dusty conditions
New Hollands unique cooling system design, where
radiators are placed forming a box rather than the
traditional approach of having them overlapped, ensures
maximum cooling efficiency and makes it easy to clean the
radiators.
For the Recycling industry, where conditions are
particularly dusty, New Holland has gone one step further
to avoid clogging of the radiators and the consequent
machine stoppages: the radiator in the W170C Recycler is
built with more space between the fins so that dust and
debris are easily blown away by the reversible fan.
In addition, the cooling box is mounted behind the cab,
far from the rear of the machine and from the ground, away
from the dust. This placement is possible because of the
rear-mounted engine, which has the added advantage of
easier maintenance from ground level all round the back
of the loader. This design results in a bigger load in your
bucket, making the W170C the most productive loader in
the 15-ton class today.

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NEWS & REPORTS


A full package of protections for the
toughest working environment
Wood and solid components in waste can cause
damage to the machine, if they fall from the bucket onto
the lifting cylinders or the windshield, or if they get stacked
in the machines articulation or under its belly. The W170C
Recycler comes with a full package of protection guards
for hoses, lights, cylinders, transmission shaft, fuel tank,
windscreen, axles, front and rear chassis to ensure the
operators safety, enhance the machines durability and
protect its residual value.

More power and fuel economy with SCR


Tier 4 interim solution
The advantage of New Hollands Selective Catalytic
Reduction (SCR) after-treatment solution lies in the high
combustion temperatures and the elimination of exhaust
gas recirculation, which allows for optimised engine
combustion. The result is more power density with less
fuel; the engine delivers 950 N.m at 1300 rpm with just 6.7
litres; the high combustion temperatures cut particulates
emissions by 90%. .

More uptime with SCR


SCR doesnt require a Diesel Particulate Filter (DPF),
so that no fuel is used to burn PM in a DPF: it all goes to
push in the pile. The machine never needs to stop for a
parked DPF regeneration, so no time is wasted. Moreover,
the operator can turn the key and stop working at any
time, as there is no need to wait for the DPF to complete
regeneration, which can require up to 50 minutes. All this
results in optimised uptime, which is particularly valuable in
recycling operations that typically work round the clock.

More safety indoors with SCR, the spark


stopper
A further benefit of New Hollands SCR solution is
greater safety on recycling jobsites, which are typically
vulnerable to fire ignition risks: the system sprays AdBlue
fluid in the exhaust to reduce NOx emissions by 50%, killing
the sparks in the exhaust in the process. In addition, the

Issue 01 | 2013

maximum temperatures reached by the catalyst are about


50% lower than those of a DPF during regeneration, further
lowering the risk of fire ignition.

More pushing power and faster cycles


with EcoShift
The EcoShift consists of three elements, which add up
to maximum efficiency and fast cycle times. The lock-up
of the torque converter is activated automatically during
travelling, eliminating viscous losses, resulting in higher
efficiency and 12% more pushing power available in second
gear and faster acceleration. It is activated from 7km/h,
when the second gear is engaged in order to maximise
efficiency. It also enables the operator to climb steep
slopes without downshifting to first gear. The five-speed
transmission enables the operator to work at lower rpm and
fully use the engines outstanding torque, resulting in more
efficiency and faster cycle times. When braking, power
inch prevents bouncing due to the automatic transmission
cut off; on slopes, it acts as a hill holder, increasing the
operators comfort and reducing fatigue.

More traction and less tire wear with


heavy duty axles with open differentials
and 100% front diff lock
The open differentials mean that no friction is applied
to reduce wheel slip, resulting in less tyre wear and lower
energy losses. The front differential lock means that 100%
of the available torque goes to the wheel with adherence
a big step up from the 60% of a limited slip differential.

Even more fuel economy with ECO Mode


and ECOSTOP
The W170C also features a new ECO working mode,
which optimises engine curves and gear shifting strategy,
achieving as much as 25% lower fuel usage than the
MAX mode. Fuel efficiency is further enhanced with the
ECOSTOP feature, which automatically shuts down the
engine and the electric system after 5 minutes of idling, so
there is no fuel waste and the turbocharger has the time to
slow down and cool before it is turned off.

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More cost savings with the W170C
Recycler
All these features make the W170C Recycler the best
wheel loader available for recycling operations, as it
offers:



The most fuel efficient tier 4 interim technology:


SCR
The most fuel efficient transmission: Ecoshift
The most reliable cooling system for dusty jobsites:
the Heavy Duty Cooling Box
And a host of cost saving features such as
ECOSTOP, ECO Mode, open differential with front
diff lock and a full package of protections

New Holland Construction is a global, full-line


construction equipment brand, with a network of 800
dealers and more than 2,100 outlets in 100 countries.
The company brings together the strength and
resources of its worldwide commercial, industrial
and finance organizations. Thanks to the experience
of its foundation heritage brands, New Holland can
proudly point to quality, technologically state-ofthe-art products that are fully compliant with safety
standards and environmental regulations. New
Holland Construction is a brand of CNH Global N.V.,
a majority-owned subsidiary of Fiat Industrial S.p.A.
(FI.MI).
More information can be found on line at
www.newholland.com.

FOR MORE INFORMATION AND CONTACT:


C2 Marketing fr ALARCON & HARRIS
Lutz Holthaus
Tel: +49 (0)2392 913 465
Tel: +49 (0)2392 913 464
eMail: presseservice@c2marketing.de
Internet: www.newholland.com

New Holland: W170C Recycler

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NEWS & REPORTS


ContiTech AG

bauma 2013: ContiTech Presents FutureOriented Product Solutions


MegaPipes expand the range of applications for closed-trough belts
Hose lines for commercial vehicles and industrial applications
ATEX-certified air springs for improved safety
Elastomer bearings reduce vibrations in systems and vehicles

With an external diameter of 750 mm to


900 mm, the new MegaPipes double the flow
rates compared to conventional closed-trough
belts. They are available as textile belts or steel
cord belts. (Photo: ContiTech)

Environmentally friendly, energy- and cost-efficient


solutions for the mining sector as well as for construction
machinery and plant construction are the focus of
ContiTechs appearance at the bauma 2013 trade show.
In addition to conveyor belts and sustainable conveyor
belt solutions, air spring systems, hose lines, and vibration
technology for industrial vehicles and plants can be seen
at stand 301/402 in hall B2.

First Choice for Conveyor Belt Technology


In keeping with the motto ContiTech Conveyor Belts.
First Choice, the ContiTech Conveyor Belt Group is
presenting innovative and environmentally friendly
conveyor belt solutions. With an external diameter of up
to 900 mm, the new MegaPipes double the capacities
compared to conventional closed-trough belts and even
enable the transport of crushed ore downstream of the
primary crusher or of bulky goods in the industrial sector
applications. Their special design allows the angle
of inclination of the closed-trough belt systems to be
increased by up to 45, depending on the bulk material

Issue 01 | 2013

properties. Another trade fair highlight comes in the form


of the conveyor belts specially developed to transport
hot goods, even at extremely high material temperatures.
Through the use of an innovative insulation layer in the belt
construction, heat transmission is lowered by up to 40C,
while the total weight of the conveyor belts is significantly
reduced. The business unit is also presenting the extremely
low-stretch EPP textile belts CON-MONTEX and CONBITEX, as well as the TransCord conveyor belts, which
offer greater flexibility compared to conventional steel
cord conveyor belts with the same conveyor strength
thanks to their special steel cord construction. In the
area of steep and vertical conveyor belts, the Conveyor
Belt Group is presenting the successful FLEXOWELL
product line and POCKETLIFT as the only continuous
conveyor system for stroke heights of up to 700 m and
capacities of up to 5000 t/h. Both systems are among the
groundbreaking innovations in this market segment. The
company is also presenting Conti Secur PREMIUM, an
innovation in adhesive technology. In line with the motto
One step one solution, the new adhesive has just one
component instead of two, which means that it can be
used immediately and for long periods.

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NEWS & REPORTS


New Segment Bundles Skills
At bauma, ContiTech Fluid Technology is introducing
the powerful new Commercial & Industrial Vehicles (CIV)
segment. It consolidates the business units expertise for
all media flows in the fields of commercial vehicles and
industrial applications. At bauma, CIV is presenting further
developments in its SCR hose line systems with heatable
quick connectors. Highly flexible hydraulic hoses made
of rubber are indispensable components for hydraulically
powered excavators, loaders, cranes, and dumper trucks.
ContiTech also provides hydraulic solutions made of
plastic.
Preformed polyamide oil and fuel lines are characterized
by their flexibility and media resistance. ContiTech Fluid
Technology has developed ultra heavy-duty fuel lines
specifically for new high-performance engines. They
can withstand pressures of up to 35 bar and operating
temperatures of up to 130C.

Air Actuators and Air Springs 80 mm to


950 mm in Diameter

and drivers cabs, will also be displayed at the stand.


Comprising two elastomer bodies and a steel tube, the
mounting element is not only cost-effective but also
ensures good acoustic decoupling for a load range from
20 kg to 500 kg.

FOR MORE INFORMATION AND CONTACT:


Mario Tpfer
Head of Technical Media Relations, ContiTech AG
Vahrenwalder Strae 9
D-30165 Hanover
Tel.: +49(0) 511 938-1304
Fax: +49(0) 511 938-1305
eMail: mario.toepfer@contitech.de
Jens Fechner
Director Market Communications,ContiTech AG
Vahrenwalder Strae 9
D-30165 Hanover
Tel.: +49(0) 511 938-14019
Fax: +49(0) 511 938-14025
eMail: jens.fechner@contitech.de

At bauma, ContiTech Air Spring Systems is mainly


exhibiting one-, two- or three-convolution bellows with
diameters of 80 mm to 950 mm. They fulfill the requirements
for ATEX certification. These products can be used in
potentially explosive areas (equipment group II) as category
2 and 3 equipment, in T1 to T4 temperature ranges and in
atmospheres containing gas or dust. For over 50 years,
ContiTech air springs and air actuators have been used for
a wide range of purposes, such as suspension of stationary
machines. Especially when used under harsh operating
conditions, ContiTech air springs and air actuators impress
with their unique product characteristics and long service
life.

Elastomer Bearings for Industrial


Vehicles and Plants
At bauma 2013, ContiTech Vibration Control, the
specialist for vibration- and noise reduction, is presenting
ring elements with external diameters of 65 mm to 256
mm. These elements can be used in the most diverse
applications and for loads of up to 82,000 N. Bushings
compensate for rotational movements in drivers cabs and
ensure a much more comfortable ride for passengers. The
SCHWINGMETALL flange components, which are particularly suited to the suspension of engines, assemblies

Issue 01 | 2013

Neben den millionenfach bewhrten


SCR-Leitungen bietet ContiTech auch eine
weiterentwickelte zweite Leitungsgeneration
mit beheizten Quick-Connectoren an. (Foto:
ContiTech)

Alongside its SCR lines tried and tested a million times over
ContiTech also offers an advanced second generation version with
heated quick con-nectors. (Photo: ContiTech)

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NEWS & REPORTS


ContiTech AG

ContiTech at the Hannover Messe:


Success with Sustainable Products

ContiTech presents sustainable products for machinery and plant engineering


Energy supply and agricultural machinery, two key issues for Russia, the trade
shows partner country
Electrically powered two-wheelers a promising future market
WeP Partner Concept celebrates 10th anniversary

Under the We care! slogan


ContiTech is showing how its systems
help safeguard supplies for people
worldwide - above all in agricultural
machinery. (Photo: ContiTech)

Under the We care! slogan, ContiTech AG is showcasing


its comprehensive technological and developmental
expertise in the manufacture of sustainable products for
machine and plant engineering at the Hannover Messe
(April 8 - 12). The technology companys approx. 500square-meter booth (F18 in hall 6) provides an overview
of whats new in rubber and plastic, the materials of the
future. This year, ContiTech has boosted its presence at the
Messe with a booth (B23 in hall 25) devoted to drivetrain
technology at the leading trade fair Motion, Drive &
Automation. On display there are drive solutions for
mechanical engineering applications and two-wheelers
as well as vibration isolation components and hose lines.
Our presence at the Messe and our principle of
Engineering Green Value underscore the claim we make
of contributing to the general well-being of society,
affirms Heinz-Gerhard Wente, CEO of ContiTech AG. With
our expertise, our high level of flexibility, and our quality
standards, we intend to up the quality of human life.
Under the We care! slogan ContiTech is showing how its
systems help safeguard supplies for people worldwide: in
the food and beverage industry, in the provision of clean
water, in the operation of irrigation systems, and, above all,

Issue 01 | 2013

in agricultural machinery and in the reliable extraction and


transfer of raw materials. ContiTechs We care! slogan also
points to the companys reliance on eco-friendly technology.
Examples of this are hoses for the purification of tractor
exhaust gases, ultra efficient drive belts for harvesters, or
a specific technology for straw balers.

Driving the future: On the road and in the


machine-building industry
The ContiTech Power Transmission Groups presentation
at the Hannover Messe focuses on heavy-duty belts for
applications in machinery and plant engineering, in twowheelers and in new eco-friendly drive belts. On view for
the first time is a new high-performance polyurethane
timing belt with carbon cord as tensile member. Its ultra
reliable force transmission capability is paired up with high
resistance to wear and abrasion. ContiTech has expanded
its range of eco-friendly drive belts marketed under the
BlueConcept label. The label stands for environmentally
compatible and healthful industrial applications. In the
future, a multiple V-ribbed belt will also be available.

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NEWS & REPORTS

This year, ContiTech has boosted its


presence at the Messe with a booth (B23
in hall 25) devoted to drivetrain technology
at the leading trade fair Motion, Drive &
Automation. (Photo: ContiTech)

The showing is complimented by drive belts for twowheelers the full gamut, from motorcycles and scooters
through to bicycles equipped with electric motors. Going
forward, the topic of individual mobility in metropolitan areas
will continue to grow in importance and with it the demand
for electrically powered two-wheelers. The ContiTech
Power Transmission Group has developed a drive system
for this purpose that replaces the classical chain with a
drive belt with a host of advantage for consumers. The
drive belts and matching pulleys are developed in close
collaboration with manufacturers and sales partners in
the two-wheeler industry. We are growing worldwide,
not only with our high-tech belts for machinery and plant
engineering but in the two-wheeler market as well, notes
Konrad Mller, head of the Power Transmission Group
business unit. Our wide-ranging competence in the area
of drive belts makes us a coveted partner.
Also available for viewing at the ContiTech booth in hall
25 are hoses for compressors and large hoses for use at
construction sites as well as air suspension systems and
ContiTech SCHWINGMETALL rubber-to-metal-bonded
components for reducing vibrations in industrial vehicles
and machines.

Russia - partner country at this years


Messe
Russia, this years partner country, will also play a role
at the ContiTech booth. ContiTech serves the Russian
market from its sales office in Moscow. Technology from
ContiTech Air Spring Systems will, for example, keep things
moving at the 2014 Winter Olympic Games. Deployed in
buses, express trains, and ropeways, too, products from

Issue 01 | 2013

ContiTech will transport a world audience to and around


the event. For decades now, ContiTech Fluid Technologys
Dunlop Oil & Marine segment has been a well-known
name in the Eastern European energy industry thanks to
its high-performance hoses for the oil and gas industry.
ContiTech is, moreover, currently constructing a new plant
in Kaluga, Russia, 170 km southeast of Moscow. Slated
to go into operation in December 2013, the new plant
will manufacture automotive air-conditioning and powersteering lines.

ContiTech makes added value tangible


For the tenth time, select ContiTech supplier partners will
present their products at the trade show booth. Together
with ContiTech, these value-added partners demonstrate
how very important the interplay among all industry
partners is in creating a high-quality product. Technologies
range from special elastomers through to communications
technology.

FOR MORE INFORMATION AND CONTACT:


Mario Tpfer
Head of Technical Media Relations, ContiTech AG
Vahrenwalder Strae 9
D-30165 Hanover
Tel.: +49(0) 511 938-1304
Fax: +49(0) 511 938-1305
eMail: mario.toepfer@contitech.de

Jens Fechner
Director Market Communications,ContiTech AG
Vahrenwalder Strae 9
D-30165 Hanover
Tel.: +49(0) 511 938-14019
Fax: +49(0) 511 938-14025
eMail: jens.fechner@contitech.de

www.advanced-mining.com

162

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NEWS & REPORTS

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Issue 01 | 2013

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163

NEWS & REPORTS


BAUMA 2013 - Messe Mnchen International

New developments enhance the future capability of the construction, building


materials and mining industry

bauma INNOVATION AWARD 2013:


nominees for the bauma Innovation Award 2013!

BAUMA Innovation Award


The nominations for the bauma Innovation Award 2013, which
is being presented as part of bauma, the International Trade
Fair for Construction Machinery, Building Material Machines,
Mining Machines, Construction Vehicles and Construction
Equipment, have been selected. The 15 nominated innovations
were announced at the press conference held at the bauma
Media Dialog on January 29, 2013 in Munich, by Johann Sailer,
President of the VDMA Construction Machinery and Building
Materials Machinery Association.
The award is divided into five categories. Out of a total of
156 submissions from Germany and abroad, the jury selected
three groundbreaking innovations per category to go through
to the final round. Editors of trade journals participating in the
bauma Media Dialog will be voting for their favorites from this
selection on January 29 and 30, 2013.
High-ranking international guests from business and
politics are expected to attend the award ceremony, honoring
the winners and the nominees, on April 14 in the AllerheiligenHofkirche (Court Church of All Saints) in the Residenz Palace
in Munich. Most of the new developments will also be on
show at bauma. The trade show takes place from April 15 to
21, 2013, in Munich.

Category: Machinery


Revolution in underground mining the Mobile Tunnel


Miner, Aker Wirth GmbH, Erkelenz
Pipe Express - a new semi-trenchless method for installing
pipelines, Herrenknecht AG, Schwanau
JFI Method: Fully automated production of multi-layer
concrete elements, Sommer Anlagentechnik GmbH, Altheim

Category: Machinery components




Tablet PC transferring the digital workplace to the


construction machine, Bauer Maschinen GmbH,
Schrobenhausen
Fume Extraction System,, Volvo Construction Equipment,
London/Great Britain
AutoPilot Field Rover 3D system for controlling offset
slipform pavers, Wirtgen GmbH, Windhagen

Category: Construction process/Construction


work


Monopile foundation for tidal engine turbine offshore site


in Scotland, Bauer Spezialtiefbau GmbH
Using revolving tower cranes to erect hybrid-energy
wind towers in a fast construction time, Max Bgl
Bauunternehmung GmbH & Co KG, Sengenthal
PAST: reliable, automated road-building improved
function along the whole building process chain, Hermann
Kirchner Bauunternehmung GmbH

Category: Research


Online grain size analyzer, Technical University of Clausthal


Parallel kinematics (HEXAPOD) for working equipment on
mobile machinery, Technical University of Dresden
Computer tomography enables orientation analysis of
steel fibers in reinforced concrete, Technical University of
Kaiserslautern

Category: Design


Liebherr Compact Loader, Liebherr-Werk Bischofshofen,


Bischofshofen/Austria
Kaiser Walking Mobile Excavator 2013, Kaiser AG
Fahrzeugwerk, Schaanwald/Liechtenstein
EH 100 demolition breaker, Wacker Neuson Vertrieb Europa
GmbH & Co KG, Munich

The criteria used by the jury of experts in reaching their


assessment of the submissions and innovations include the
following: sustainability, practical use, contribution towards
environmental protection and humanization of the workplace,
economic benefit and performance capability combined with
energy- and cost-efficiency, and the contribution towards
enhancing the image of the construction, building-materials
and mining industries or the sector as a whole.
In 2013 the Innovation Award is being presented for the
tenth time. The competition is a joint project by the German
Engineering Federation (VDMA Verband Deutscher
Maschinen- und Anlagenbau e.V.), the German Construction
Industry Association (HDB Hauptverband der Deutschen
Bauindustrie e.V.), the Central Association of the German
Construction Industry (ZDB Zentralverband des deutschen
Baugewerbes e.V.), the German Building Materials
Association (BBS Bundesverband Baustoffe Steine und

Erden e.V.) and bauma

Issue 01 | 2013

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164

NEWS & REPORTS


Catego

bauma Innovation AWARD 2013:

Aker Wirth through to the final round - Mobile


Tunnel Miner has chances for award

ry Mac

hiner
y

he latest development from Aker Wirth, the Mobile Tunnel Miner (MTM) for underground
tunneling and mining, has been nominated for this years bauma Innovation Award. A jury of
T
experts picked the MTM as one of the three best contributions from among 156 entries in the
Machinery category. The nomination was announced officially at the bauma Media Dialogue
event, which was held in Munich, Germany end of January. The winners will be announced
officially and handed their awards in Munich on 14 April 2013.
The innovative Mobile Tunnel Miner combines the
flexibility of a roadheader with the robustness of a tunnel
boring machine. The knowledge gained from a previous
version developed and tested already by Aker Wirth is also
exploited. The nomination is a welcome confirmation of
our performance and innovation strength. Our MTM sets
a revolutionary new benchmark in underground mining,
particularly with regard to safety and efficiency, said Aker
Wirth CEO Einar Brnlund.

The bauma Innovation Award


At the internationally-renowned Innovation Award
event, pioneering innovations in construction machinery,
building material machinery and mining machinery, as
well as construction work/processes, are recognised by
the VDMA (Association of German Machinery and Plant
Manufacturers), bauma and the Spitzenverbnden der
Deutschen Bauwirtschaft (Central Associations of the

German Construction Industry). Prizes are awarded every


three years at the bauma international trade fair, the worlds
leading exhibition for construction machinery, building
material machinery, mining machinery, construction
vehicles and construction equipment. It will be held in
Munich, Germany from 15 to 21 April 2013. Prizes will be
awarded in five categories (Machinery, Machinery
component, Construction process/Construction work,
Research and Design), for each of which three
innovations have been selected for the final round. They
were presented to the international specialist journals at
the bauma Media Dialogue event with short films and in
discussion with representatives from the companies.

About Aker Wirth


Aker Wirth is one of the leading equipment suppliers, delivering
core components for the oil and gas industry as well as mining
and civil construction products for the industry. Since 1895, Aker
Wirth has been supporting the establishment of a modern and
efficient development of natural resources
and infrastructure, promoting growth and
improving the standard of living. In 2010
and 2011, Aker Wirth was awarded for an
outstanding personnel management and in
2009 and 2011 for innovative products and
solutions. Aker Wirth is a subsidiary of Aker
Solutions AS, a provider of oilfield products,
systems and services for customers for the
oil and gas industry world-wide.

FOR MORE INFORMATION AND CONTACT:

The Aker Wirth Mobile Tunnel Miner 6

Issue 01 | 2013

Aker Wirth GmbH


Klner Str. 71-73 | D-41812 Erkelenz
Simone Grnemeyer
Manager Communications
Tel.: +49(0) 2431 83-459
Fax: +49(0) 2431 83-83 459
eMail: simone.groenemeyer@akersolutions.com
Internet: www.akersolutions.com/akerwirth

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NEWS & REPORTS

bauma Innovation AWARD 2013:

Catego

ry Mac

PIPE EXPRESS from Herrenknecht nominated


for the BAUMA Innovation Award

hiner
y

ith Pipe Express the Herrenknecht AG has developed a new semi-trenchless method
for installing pipelines. In comparison with the open construction method, routes are
W
considerably narrower, no groundwater lowering is necessary and there is less impact on
nature. This has a very positive effect on the grid operators construction costs. Because of the
especially ecological and cost-efficient working method, the development of this new system
is subsidized by the German Environment Ministry. An expert jury has now nominated Pipe
Express for the bauma Innovation Award 2013.

Pipe Express is a new mechanized method for the


near-surface installation of pipelines of up to 1,000 meters
in length and with diameters of 800 to 1,500 millimeters
(32 to 60) using the half-open construction method.
A tunnel boring machine loosens the soil which is then
directly conveyed aboveground using a milling unit which
is carried along. At the same time, the pipeline is installed
underground. Since earthwork is reduced to a minimum
and no groundwater lowering along the route is necessary,
Pipe Express has very little impact on the environment.
This method is unique so far: For the installation of
pipelines with a diameter of up to 1,500 millimeters, the soil
is directly removed and not pushed aside. Pipe Express
is ideal, for example, for projects in which the groundwater
level is only a few centimeters below the terrains surface,
in mainly swampy terrain or when nature protection is of
special importance.

Issue 01 | 2013

Minimum manpower and a high degree of


work safety
The main components of the new installation system
include a tunnel boring machine that works underground,
a trenching unit with a buggy and an operating vehicle
on the terrain surface. The modular design of the entire
system allows easy transport and relocation, as well as
high flexibility in changing project conditions. The compact
system is remote controlled from the operating vehicle
and no trenches have to be dug. This means that minimum
manpower is needed, increasing work safety at the same
time.

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166

NEWS & REPORTS


Cost savings thanks to minimum earthwork
The new method has a positive influence on the
realization and renaturalization costs in projects taking
place in particularly challenging areas with unstable
ground, water-bearing layers and at great installation
depths. Compared to the conventional open construction
method, with Pipe Express the route width can be
reduced by up to 70 percent, thus reducing the necessary
earthwork. When crossing agricultural land, major losses
of harvest and thus long-term compensation payments can
be prevented compared to the open construction mode.

Environmentally-friendly installation of
pipelines

PipeExpress

By using Pipe Express, the influence of the construction


activities on the surrounding environment can be reduced
to a minimum. Acceptance by the population, land
users and land owners is improved due to the reduced
implementation of large equipment and thanks to shorter
construction periods. The natural soil structure is only
disturbed to a minimum, making subsequent recultivation
easier. No complex groundwater lowering is required along
the route and water-saturated soil layers are prevented
from drying out. In addition, as the pipeline is installed fast
and in one work step and fewer conventional construction
machines are needed, emissions of exhaust gases and
noise can be considerably decreased.

Test drillings and a first reference project


completed successfully
After Herrenknecht AG had initially carried out
test drillings on the company site at the Schwanau
headquarters over one year, the new machine technology
could be applied in a first reference project in Sevenum,
Netherlands at the end of 2012. Pipe Express has
exceeded all expectations, noted project manager
Andreas Diedrich with satisfaction and continued to
explain: The machine works with a tunnelling speed of
up to one meter per minute, which means that 500 meters
of pipeline were installed in three days. The construction
company Visser & Smit Hanab is currently building a new
high pressure gas line between Odiliapeel and Melick for
the Gasunie grid operator. On a section of this line, the
Herrenknecht innovation was put to use. Visser & Smit
Hanabs managing director Wilko Koop confirmed: I am
very enthusiastic, everything worked excellently.

Issue 01 | 2013

PipeExpress in action

PipeExpress starting area

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NEWS & REPORTS


Pipeline installation technology for all
geologies and terrains
In view of the expected extension of the worldwide
pipeline network by around 25,000 kilometers a year,
Herrenknecht AG sees itself well-positioned with its
portfolio extension, allowing the installation of pipelines for
gas, oil, freshwater, district heating or as protection pipes
for power cables in all geologies and terrains. In sensitive
areas, PipeExpress will be a quick, environmentallyfriendly and economic alternative to the open construction
method in future. The Herrenknecht AG also offers the
flexible HDD method as a tried-and-tested trenchless
technology to cross, for example, underneath rivers, roads
or populated areas in soft to very hard grounds, or the
single-step Direct Pipe method for unstable grounds.

Nomination for the bauma Innovation


Award 2013
An expert jury nominated Pipe Express in the machine
category of the bauma Innovation Award 2013. In mid-April,
the prize will be awarded in five categories. The jury will be
assessing the future business capability and the practical
relevance of the innovation. Selection criteria are economic
efficiency, increase in performance, energy and resource
efficiency as well as the innovations contribution towards
environmental protection, humanizing of the workplace
and improving the sectors image. The competition is a joint
project of the VDMA (German Engineering Federation), HDB
(Main Federation of the German Construction Industries),
ZDB (Central Federation of the German Construction
Industries), BBS (German Federation of Construction
Materials - Stones and Earth) and bauma.

The Herrenknecht AG
As the only company worldwide, Herrenknecht AG delivers
tunnel boring machines for all ground conditions and in all
diameters ranging from 0.10 to 19 meters. The Herrenknecht
product range includes tailor-made machines for transport
tunnels, supply and disposal tunnels and additional equipment
and service packages. Furthermore, Herrenknecht manufactures
drilling rigs for vertical and sloping shafts as well as deep drilling
rigs. In the year 2011, the Herrenknecht Group achieved a total
operating performance of 1,104 million euros. Since the formation
of the company in 1977, Herrenknecht machines have excavated
a total of 1,900 kilometers of tunnels in the large diameter
range of more than 4.20 meters. Around 850 Herrenknecht
Utility Tunnelling Machines are in operation around the world
constructing or laying water and wastewater systems, gas and
oil pipelines, as well as conduits for electricity, the Internet and
telephone lines. The Herrenknecht Group employs around 4,000
members of staff worldwide and is training more than 240 young
people. With 77 subsidiaries and associated companies working
in related fields in Germany and abroad, Herrenknecht provides a
comprehensive range of services close to the respective project
and customer.

FOR MORE INFORMATION AND CONTACT:


Herrenknecht AG
Schlehenweg 2 | D- 77963 Schwanau
Achim Khn
Tel.: +49(0)7824 302-5400
Fax: +49 (0)7824 302-4730
eMail: pr@herrenknecht.de
Internet: www.herrenknecht.de

Pipe Express - the method


When installing pipes with Pipe Express, a tunnel boring machine drills the tunnel for the pipeline which is installed
simultaneously. The excavated soil is conveyed directly to the surface via the milling unit and stored alongside the
route. At the same time, the trenching unit functions as a vertical connection between the tunnel boring machine and
the terrain surface. The operating vehicle accompanies the installation system and provides the entire logistics. These
include a control stand for the operator, a power unit room, a high-capacity pump and a storage container for bentonite
to reduce the skin friction between the pipe string and the ground. With the integrated crane system, assembly and
dismantling work can be done in a very short period of time. The thrust force for the excavation unit and the pipeline is
provided by a Herrenknecht Pipe Thruster.

Issue 01 | 2013

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168

NEWS & REPORTS

bauma Innovation AWARD 2013:

Catego

Sommer Anlagentechnik GmbH - JFI-Method

ry Mac

hiner
y

Fully automated production of multi-layer concrete elements

he JFI method, an innovation by Sommer Anlagentechnik and SAA Engineering, granted


with a patent in 2012, enables a highlyprecise automated production of multi-layer concrete
elements with high flexibility and productivity.
Till now the production of multi-layer concrete elements
had been performed manually in most cases. The
production of sandwich elements with a protruding facade
cladding with klinkers, tiles, handcraft and natural stone
needs much a lot of personnel and is not flexible. For this
reason the market share is also quite low currently.
This new process has been developed for the
requirements of the Russian market. But due to the
substantial advantages of this process for the production
of high quality facade elements it will increase the market
share of prefabricated concrete elements world wide.
At the end of the year 2012 the very first plant world
wide with this energy efficient, highly productive and
ressource friendly technology will be taken into operation
in the greater Moscow region. Another plant will start its
production by the end of the year 2013.
New fields of application in the production of complex
prefabricated concrete parts are opened. Different
building projects can be implemented economically.
Energy and material costs are reduced, eg by saving
plastic matrix and insulation material. By the possible use
of different facade cladding elements such as steel, stone,
aluminium, ceramics and photovoltaic the technical and
aestethical quality of the buidling projects will be improved
significantly.

The following developments have been


implemented for that purpose:
Production method for applying a joint filler
The joint filler is applied automatically to the surface of
the production pallet in a grid pattern according to the CAD
planning. The joint filler mass has the following properties:
it can form a joining contour. it does not connect with
the joining concrete. it balances the tolerances of the
production pallet. it has vibration absorbing properties
and thus protects the facade elements from damages in
the following compaction processs. the facade elements
are position-fixed. it enables sealing and balancing of
tolerances at the moulding edges.

Production method for feeding facade cladding


elements (tiles, klinker, etc) automatically to
a transport and cutting device and for placing
them automatically and precisely with a robot
on the production pallets
The cladding elements are fed to a robot cell. The robot
takes out one unit from a transporting unit (pallet, staple
etc) and feeds it directly to a cutting device or directly to

The net product for the production in the


prefabricated concrete plant is increased
and also the competitiveness of prefabricated
concrete parts over cast-in-place concrete.
By fully automated, CAD supported production
processes the efficiency of the production
process will be increased and the working
conditions in the factories will be improved.

Production method
applying a joint filler

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for

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the placing robot. The placing robot grips a group
of pre-positioned parts, drives them to the unit
and exactly into the joint filler applied before - in a
distance to be defined.

Production method enabling an


automated feeding, cutting, boring and
positioning of the insulation layer and an
automated placing of wall connectors
The insulation staples being deliverd as staples
are cut into single pieces automatically; according
to the CAD data they are cut and borings or
breakthroughs for the wall connectors to be used
are inserted. A placing robot positions the plates
on the freshly cast front layer and plugs and wall
connectors through the recesses in the insulation
plates and into the wet concrete.

Production method for feeding facade cladding elements (tiles,


klinker, etc) automatically to a transport and cutting device and
for placing them automatically and precisely with a robot on the
production pallets

Production method enabling an automated feeding, cutting,


boring and positioning of the insulation layer and an automated
placing of wall connectors

FOR MORE INFORMATION AND CONTACT:


Sommer Anlagentechnik
Alfred Strameier
www.sommer-landshut.de
SAA Engineering
Dr. Christian Hanser
www.saa.at

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bauma Innovation AWARD 2013:

BAUER Maschinen GmbH - Tablet-PC

Category Mac
ery
Componenhtin
s

n the Component category, BAUER Maschinen GmbH presents the tablet-PC for foundation
equipment, a helpful tool to facilitate communication and documentation procedures in
construction projects.
A generic tablet-PC is fixed in the operators cabin and
equipped with electronic and mechanical theft protection.
A data interface with the construction equipment and
the internet as well as various applications offer multiple
benefits for all important stakeholders of a project.
One of these apps enables the B-Tronic operator screen
to be displayed on the tablet-PC. Thus the operator can
be observed or instructed from a distant and safe position
outside the working area. Another app provides editing of
photos and screenshots, with a linked e-mail facility. The
BAUER World app includes functionality which allows
users to access the BAUER Maschinen customer centre
or the online Parts & Service catalogue. A wide range of
applications is available to optimize working procedures
on-site.
Using tablet-PCs for industrial applications is stateof-the-art. The actual innovation is the integration in the
process of construction. With this technology the digital
age is brought into construction equipment. Since 2012,
the tablet-PC can be found in all of BAUERs PremiumLine
drilling rigs, piling rigs and foundation cranes.
.

FOR MORE INFORMATION AND CONTACT:


BAUER Maschinen GmbH
D-86529 Schrobenhausen
Tel. +49(0) 8252 97-0
Dipl.-Ing. Manfred Schpf
Tel.: +49(0) 8252- 97 1302
eMail: Manfred.Schoepf@bauer.de
Internet: www.bauer.de

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Tablet-PC fr Baustelleneinsatz

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bauma Innovation AWARD 2013:

VOLVO: Fume extraction system


shortlisted for bauma Innovation Award

Category Mac
ery
Componenhtin
s

olvo Construction Equipments extractor for bituminous fumes has been shortlisted for a
bauma Innovation Award. The innovative design improves the operator environment on the
companys ABG pavers by substantially reducing fumes without significantly increasing fuel
consumption, noise or affecting visibility into the auger channel.

Volvo Construction Equipments (Volvo CEs) revolutionary


extractor for bituminous fumes is one of three finalists
in the machinery component category of the bauma
Innovation Awards. The system, which is available as an
option on Volvo CEs C-Series ABG pavers, introduces a
new way of removing fumes from the operators working
environment. The innovative feature improves the working
conditions of the operator who sits directly above the
auger channel. By delivering 83% efficiency, the system
exceeds the National Institute for Occupational Safety and
Health (NIOSH) guidelines which state that
80% of fumes should be captured. Volvos
results have been independently certified by
an environmental institute.

compact architecture. This also helps to maintain visibility


into the auger channel which is vital to ensure consistent
material flow and good quality, smooth paving.

Innovative and efficient


During the majority of operating conditions, Volvos ABG
pavers run on smart power which lowers the engine rpm

Behind the breakthrough


The pioneering system works by using
a fume intake, with a fan located directly
behind it, on both the left and right hand side
of the auger channel. The fan captures and
transports the fumes via two tubes to the top
of the paver where they are then released.
This means that the air in the operators
working environment is significantly cleaner
than was previously the case.
Volvos design is located at the back of the
machine and features a very short distance
between the intake and the fan eliminating
the need for additional piping and funnelling in
the auger channel. This increases efficiency,
prevents any loss of power and ensures that
there is no effect on the operators visibility
into the auger channel. Because extra
power is not needed, smaller fans are used.
These can be installed horizontally instead
of vertically which offers a smaller, more

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and considerably reduces fuel consumption.
The new fume extraction system continues
this environmentally friendly and fuel efficient
approach and works just as efficiently when
the machine is operated in smart power mode
as it does when the machine is working in max
power mode.
As well as increased efficiency and visibility,
another benefit of the Volvo design is reduced
noise. The difference in sound between the
system being on or off is insignificant just
0.3 decibels. This means that there is no risk of
the system distracting the operator or causing
fatigue.

FOR MORE INFORMATION AND CONTACT:


Volvo Construction Equipment Deutschland GmbH
Marketing & Communications Manager
Thorsten Poszwa
Adalperostr. 80
85737 Ismaning | Germany
Tel.: +49 (0)89 944 - 66 42 30
eMail: thorsten.poszwa@volvo.com
Internet: www.volvoce.com

Paving the way


Although there is currently no legislation
insisting pavers meet the NIOSH 80% guideline,
the Volvo system has been designed to meet
demands from customers and operators in
certain markets. Due to the modular design
of the Volvo system, it can be retrofitted to
machines already in the field.
.

Volvo Construction Equipment (Volvo CE) is a major international company developing,


manufacturing and marketing equipment for construction and related industries. Ist products,
leaders in many world markets, include a comprehensive range of wheel loaders, hydraulic
excavators, articulated haulers, motor graders, and soil and asphalt compactors, pavers,
milling machines, compact equipment and material handling equipment. Volvo CE is part
of the Volvo Group, the worlds largest manufacturer of diesel engines in the 9 to 18 liter
category. The Volvo Group is one of the worlds leading manufacturers of trucks, buses and
construction equipment, driver systems for marine and industrial applications, aerospace
components and services. The Group also provides complete solutions for financing and
related services.

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bauma Innovation AWARD 2013:

Category Mac
ery
Componenhtin
s

Nominated for the bauma Innovation Award 2013 The

Wirtgen AutoPilot Field Rover revolutionizes road construction

s the leading manufacturer of road construction machinery, Wirtgen GmbH is renowned


for its pioneering technologies and innovations. With the Wirtgen AutoPilot Field Rover,
the company has now launched a technical development that for the first time enables fully
automatic, stringline-free concrete paving. This system will enable road construction companies
to complete jobs much more easily, quickly and, above all, economically. The jury of the bauma
Innovation Award 2013 also deemed the AutoPilot Field Rover a pioneering development, and
nominated it in the Machinery Component category.
When monolithic profiles such as concrete safety
barriers or curbs are paved today, digital terrain models
are created and so-called stringlines are secured in the
ground along the profile. During paving, these are used
by the machine for orientation purposes a very timeconsuming method.

Fully automatic paving with the AutoPilot


Paving is much quicker with the Wirtgen AutoPilot. The
3D control system comprises a computer that is integrated
in the machine and an intuitive control panel. Two GPS
receivers mounted on the machine communicate with
a GPS reference station on the job site. A digital terrain
model is not required, as surveying and programming is
carried out on the spot.
Conventional stringline-free 3D systems currently
available on the market can only be operated by personnel
trained in surveying, while the AutoPilot Field Rover is
designed for simple operation by the machine operator,
rendering special training unnecessary.

AutoPilot Field Rover: Stringlines are a thing


of the past
But what happens if a hydrant is positioned incorrectly
or a gully is located 10 cm away from its marked site? With
the traditional stringline method, the user modifies the line
on the job site. This is also poses no problem for the Field
Rover. The Field Rover comprises a GNSS receiver and a
data collector on which the software developed by Wirtgen
is installed. As during normal survey work, the section to
be paved is staked out with a plumb rod and individual
measuring points defined. The highlight of the Field Rover
is that the software calculates the optimum course on the
basis of the measured points, creating a virtual stringline,
so to speak. The data are saved on a USB stick that is then
simply connected to the machine. It is not necessary for
the operator to enter any additional data by hand. The
Wirtgen slipform paver then automatically moves to the
starting point calculated during the survey, and from there
moves along the defined course.

The AutoPilot Field Rover has been


nominated for the bauma Innovation
Award in the Machinery Component
category, as the jury regards this
new development as a pioneering
development for road construction

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If the concrete profile is to be paved up to existing
roadway edges, the user can calculate the optimum virtual
stringline within minutes. For the first time ever, it is now
truly possible to eliminate the conventional stringline in
practical applications.
Road construction companies stand to benefit in many
ways for example the Field Rover lowers paving costs
considerably in comparison to conventional methods. As it
bases its calculations on the actual job site measurements
and does not rely on construction drawings, it achieves a
higher degree of paving accuracy and quality. In addition,
the slipform paver can automatically negotiate obstacles.
Apart from enhancing safety on the job site, this feature
also brings further cost reductions, as machine damage
that frequently occurs when the machine drives over
obstacles is effectively eliminated.

FOR MORE INFORMATION AND CONTACT:


Wirtgen GmbH - Press and Public Relations
Michaela Adams, Mario Linnemann
Reinhard-Wirtgen-Strae 2
53578 Windhagen | Germany
Tel.: +49 (0)26 45 - 1 31-0
Fax: +49 (0)26 45 - 1 31 499
eMail: presse@wirtgen.com
Internet: www.wirtgen.com

With the AutoPilot Field Rover, Wirtgen is introducing


3D technology for everyone. The price of the system is
significantly lower than that of existing 3D systems, as the
Wirtgen system is optimally integrated in the machine and
optimized for the respective application. Whats more, this
ingenious tool is very easy to use, so that there is no need
to consult a survey technician.

The job site set-up for 3D control with


the innovative Wirtgen AutoPilot: Highest
precision is guaranteed

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Catego

ry Con
procestructio
ss
n

bauma Innovation AWARD 2013:

BAUER Spezialtiefbau GmbH


Drilled Monopile Foundation for a Tidal Turbine

number of BAUER Group companies were involved in a project in the summer of 2011 to
install a monopile into the sea bed as the foundation for a tidal turbine. The contract was
executed by BAUER Renewables Ltd. with the help of its parent Bauer Spezialtiefbau GmbH.
Tidal flows are a good source of renewable energy,
as they provide a regular and predictable output. In the
North Sea off Scotland, close to the Orkney Islands, a test
field of the European Marine Energy Centre (EMEC) has
been established for such projects aimed at generating
renewable energy.

FOR MORE INFORMATION AND CONTACT:


BAUER Maschinen GmbH
D-86529 Schrobenhausen
Tel. +49(0) 8252 97-0
Retrieval of the drilling unit after a successful operation

In order to install the monopile foundation, Bauers


engineers designed an entirely new drilling rig which is
lowered to the sea bed and is operated hydraulically from
on-board a floating vessel. The new rig was designed by
Bauer Maschinen, and within just a few months was ready
for operational use. Its name: the BSD 3000 BSD standing
for Bauer Seabed Drill. Initial sketches were produced in
October 2010, and in March 2011 manufacturing of the rig
began. In the subsequent phase the project was subject to
strict timing constraints. Every day was planned exactly:
for testing, transportation from Hamburg to the UK port,
transfer from the port of Scrabster to the drilling location,
and for the drilling phase itself.
The work on-site had to take account of the tides,
waiting for the hour or two in which ebb turned to flood
and vice versa. Only during that period of relative calm
was it possible to lower the key components of the rig: the
drilling template with casing oscillator, guide casing and
drilling tool. The actual drilling was possible even when the
sea was rough. The special ship was held in position by a
propulsion system based on GPS.
Thanks to detailed preparation, the drilling operation
ran almost perfectly. The drilling was carried out using a
full-face roller bit with heavy weights. The cuttings were
transported to the surface by an air-lift system. The torque
was provided by a modified BG 28 rotary drive. At a depth
of around 37 meters underwater, a 23 metre long monopile
with two metre diameter was grouted into an 11 metre deep
rock socket with high-strength mortar. The one megawatt
turbine will be installed approximately 12 metres above the
sea bed a depth at which it is able to make optimum use
of the tidal flows.

Three dimensional drilling


operation schematic of the
seabed drilling equipment
BSD 3000

The complete seabed drilling


equipment BSD 3000 on the pier at
Scrabster, Scotland

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bauma Innovation AWARD 2013:


Max Bgl Wind AG Hybrid-energy wind towers

Catego

ry Con
procestructio
ss
n

A successful pilot project in Bischberg:


To be able to reach areas with high wind
speeds, with its hybrid wind turbine towers
made from reinforced concrete and steel,
Max Bgl Wind AG reaches hub heights of
150 metres. This new generation of high
performance wind energy systems is also bringing
a new assembly concept a long with it. The towers
are being constructed with specially modified, selfclimbing revolving tower cranes.

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bauma Innovation AWARD 2013:

Catego

ry Con
procestructio
ss
n

HERMANN KIRCHNER Bauunternehmung GmbH PAST (Process-Reliable Automated Road Construction)


Increased quality and durability of asphalt roads
Reduced construction-related congestion
Diminished burden on public budgets
The cooperative research project PAST (Prozesssicherer
automatisierter Straenbau) [Process-Reliable Automated
Road Construction], which was concluded in 2012 with a key
role being played by several STRABAG Group companies,
aims at making decisive improvements to important
functional properties of asphalt roads such as noise
absorption, evenness, grip and durability by eliminating
quality-influencing weaknesses during the construction
and logistics processes. This involved around four years of
intense research to develop state-of-the-art approaches
in automation from which machine technology innovations
were derived for the entire construction process chain.
Practical testing was carried out along trial sections on
four motorways and two federal highways in Germany.

In 2010, the 15 procedures and techniques (so-called


demonstrators) which had been developed to date were
subjected to a first practical test along a trial section of
the German A4 motorway near Jena. The procedures and
construction techniques were then further refined and
successfully tested at five additional trial sections.

Quieter, safer, more durable, and equipped with


intelligent sensor technology: this is the road of the future.
The innovations will benefit not only road users, but will
also help to reduce the burden on public budgets, minimise
construction-related congestion, which results in an
estimated 4.4 billion hours of lost time, and shorten the
intervals between road maintenance.

A further innovation is the use of data transponders


placed in the asphalt during the paving process. The
transponders will not only store all relevant construction
data and material values, but will also allow the asphalt
temperature and thickness to be measured, stored and
read as often as desired. This is not only of immense
importance as information for the production process, but
as part of an intelligent road sensor system can also serve
as a universal source of information and early-warning
system (e.g. during icy conditions or to determine the
current road conditions).

The recently concluded interdisciplinary research


project PAST participants included two German
universities, several industry partners, the German
Federal Highway Research Institute (Bundesanstalt fr
Straenwesen BASt) as well as the STRABAG Group
companies Deutsche Asphalt GmbH and Hermann Kirchner
Bauunternehmung GmbH as project leader shows that
innovative approaches to this subject already exist.
The aim of the project is to identify and eliminate nearly all
quality-reducing factors during the construction of asphalt
roads. The goal is to produce high-quality, long-lasting
road surfaces through the use of largely standardised and
automated processes along the entire process chain, from
the mixing plant to the construction site. The necessary
construction techniques were developed in a series of
steps over the duration of the project (2008-2012) and can
be used in the construction of roads following their testing
and conformance to standards.

Issue 01 | 2013

The Brandenburg Roads Agency (Landesbetrieb


Straenwesen Brandenburg) commissioned KIRCHNER
as project leader to provide maintenance works along a
seven-kilometre section of the A111 motorway near Berlin.
Nine different asphalt types were laid and, as part of the
PAST project, will be measured, observed and assessed
over the whole service life.

Our federal highways and motorways show significant


deficits in terms of quality. This makes analysing and
improving the processes so important, says Prof. Josef
Kunz, director of the road construction department at the
German Federal Ministry of Transport, Building and Urban
Development (BMVBS), convinced of the research projects
innovative approach. The necessity to improve the quality
is clear to see. Growth forecasts predict 20 percent growth
of non-commercial and 40 percent growth of commercial
traffic by the year 2015.
A complete contemplation of the process chain not only
includes the use of weak point analyses and improvements
in construction techniques, but also the testing of different
asphalt compositions. Various mixtures were produced,
including the first-ever layed asphalt with a porous surface,

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and an integrated gritting was carried out before the first
rolling. The general objectives here are to improve road
quality in terms of noise reduction, lightness and grip with
reduced costs and increased durability.

Overview of the technological and procedural


developments achieved to date as part of the
cooperative research project PAST:








Targeted, segregation-free filling of the vehicles at


the mixing plant
Thermally insulated truck container with integrated
temperature sensors
Shock-absorbent docking system to paver
Optimised mixture transport in paver with
horizontally movable bunker wall and auger
modification
Data collection and analysis using roadway
transponders
Reflector-laying machine to determine layer
thickness
Automation of road rolling
Interactive real-time communication between
roller and paver regarding production management
/ control
Asphalt production and long-term roughening with
integrated gritting

General facts and figures


Project leader:
HERMANN KIRCHNER Bauunternehmung GmbH
Project partners:
Deutsche Asphalt GmbH, Carnehl Fahrzeugbau GmbH,
Dynapac GmbH, Moba Mobile Automation AG, FH Kln, TU
Darmstadt, Bundesanstalt fr Straenwesen (BASt)
Financed by:
Bundesministerium fr Wirtschaft und Technologie
(BMWI)
Project sponsor:
TV Rheinland
Trial sections:
A4 Jena, A111 Berlin, A33 Hilter, A19 Gstrow, B16
Unterhausen, B184 Dessau

The constant improvement of construction materials and


construction processes, and the use of specially adapted
machinery and equipment, make the research results
clear to see and the project experts are already aiming to
continue the research project this year.

FOR MORE INFORMATION AND CONTACT:


Hermann Kirchner Bauunternehmung GmbH
Thomas Gallistl
Hermann-Kirchner-Str. 6
36251 Bad Hersfeld
Tel.: +49 6621 162-335
eMail: thomas.gallistl@kirchner.de

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bauma Innovation AWARD 2013:


Clausthal University of Technology Online Grain Size Analyzer

Catego

ry Res

earch

he innovation consists of utilizing the physical principle of proportionality between pulse


intensity and grain size in dynamic processes for online recording of grain size distribution
of mass flows in belt conveyor systems, as well as in hydraulic and pneumatic transports in
pipeline and in construction of a globally new analyzer for process monitoring, system control
and quality assurance during processing steps: cutting, sorting, classification and finishing.
Technical and economical optimization of processing
and quality improvement of commodities calls for an exact
knowledge of grain size distribution of mass flows before
and after each step of the process, as it is essential to ensure
quality and process control. Apart from the very narrow
grain spectrum in a range of fine to super-fine grains, for
which optical measuring methods deliver an online particle
measurement, there exists no method, which allows for a
representative online-screening analysis of mass flows in
dynamic processes for the entire grain spectrum various
mixing states (solid, solid-liquid mixture and solid-air
mixture). Currently, the recording of the grain spectrum
before and after each step in processing is done through

Issue 01 | 2013

manual sampling from the mass flow. Samples are then


often dried before being analyzed in the laboratory with
common screening machines. This universally applicable
new online grain size analyzer can be applied to a wide
range of grain sizes and eliminates time-consuming and
cost-intensive sampling and laboratory analysis, as well
as ergonomic and occupational safety concerns during
sampling, the health impact of dust formation during
sieving quartzous product in the laboratory.
The forward-looking significance of this innovation is
intensified through the fact that the innovation also offers
a continuous automatic screening analysis of the mass
flow and ensures online-control and monitoring of plants

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NEWS & REPORTS


and product quality. Application of several sensors in a
process chain even allows for a holistic system analysis.
It should be emphasized that this innovation offers
an extensive range of application in many branches
of engineering industry, in which any type of granular
material is produced or processed. Currently the following
branches are benefitting from this innovation:


Mining and civil engineering


Machine industry
Raw material processing industry

This new development has been installed in two mines


and is currently being used for steering of processing
machines. Further plants are planned to be equipped with
the device and currently tests are being conducted for
application in gypsum, salt and potash industry. The device
has also been used in tunnelling.

Advantages of the online grain size


analyzer









Economical and technical advantages


Increase of global competition in machine industry
Increase in quality of plants as a result of optimum
mode of operation
Reduction in personnel costs
Reduction in maintenance costs
Reduction in energy costs
Process control, weak point analysis and diagnosis
Increase in product quality
Reduction of costumer complaints
Increase of efficiency in raw material processing

Issue 01 | 2013

Humanization of the work place




Substituting manual sampling


Eliminating danger of accidents in manual sampling
from mass flows
Elimination of dust formation during manual sieving

Environmental advantages

Reduction of waste
Reduction of noise and dust formation.

Online Grain Size Analyzer


One of the main tasks of process monitoring, system
control and quality assurance in various branches of
the industry is to determine the grain size distribution
of granular material. The range of tasks extends from
pharmaceutics and food production to chemistry, as well
as to construction and mining industry. There is a central
role to processing of mineral raw material, particularly in
mining, since here the processes of crushing, sorting and
grading, which are directly linked to the distribution of
grain size of the material, can be optimized, supervised and
controlled. The capturing the grain spectrum of a material
mixture before or after each process step is usually done
through sampling and analysis through well-established
screening machines in the laboratory, often preceded by
preparation of the specimen, for example drying. Since
it is difficult to determine grain size of dust and ultrafine
grains, laser-based analysers, which are integrated in
the laboratory or partly in the process chain, have been
developed. However, the timeconsuming and costly sampling from
the process cycle with subsequent
laboratory analysis, as well as the
limited range of application and
the sensitivity of optical methods
call for the development of a robust
measuring system for use in a
broad range of application for the
online analysis of the grain size
distribution of granular material. The
development and application of a
new method to determine grain size
is based on pulse-induced vibration.

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Measuring Principle

Currently several plants are in industrial operation:

During its transport in various media collisions of


granular material with solid bodies generate impulses,
that evoke oscillations in those solids. The characteristics
of the oscillations are directly proportional to the pulse
intensity, and in case of the same density of the granulate
material, they are directly proportional to the grain size.
The correlation of the inter-class time-bound intensities
of the signals results in a distribution, which is directly
proportional to the distribution of the grain spectrum that
has generated vibrations in the analysed timeframe. A proactive one-time calibration of the system allows for the
assignment of signals to the respective grain categories,
making an online grain size analysis possible.

Plant control in the quartz sand processing


(hydraulic tube conveyor)
Control of processing plants of a sand-and-gravel
operation (conveyor belt)
Laboratory analysis of sand and gypsum products
(pneumatic tube conveyor)

Range of uses and applications


The new development is available for on-line particle
size analysis in bulk flow on belt conveyors and in hydraulic
or pneumatic tube conveying.
The device is used for process monitoring and control
as well as quality assurance for all processing operations
such as crushing, sorting, classifying and refining.

FOR MORE INFORMATION AND


CONTACT:
Clausthal University of Technology
Univ.-Prof. Dr.-Ing. habil. H. Tudeshki
Institute of Mining Engineering
Clausthal University of Technology
Erzstrasse 20
D-38678 Clausthal-Zellerfeld
Tel.: +49(0) 53 23 - 72 22 25
eMail: tudeshki@tu-clautshla.de

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bauma Innovation AWARD 2013:


Technical University of Dresden HEXAPOD- Parallel kinematics

Catego

ry Res

earch

pplicability, performance and safety of mobile machines are determined by their work
equipment. Thus it contributes heavily to the technical solution of construction as well as
forestry, agriculture and transportation machines. Within the scope of a research project funded
by the BMBF a parallel kinematics, also known as Hexapod has been developed to be applied
as device interface (e.g. tractor), as linkage for blades (e.g. grader) and to combine different
equipment versions for wheel loaders. The latter shall be used to demonstrate the numerous
advantages that come with this innovation.
Because of its mobility and large variety of tools the
wheel loader as a heavy equipment machine is adjusted
to different processes (e.g. loading, mixing, milling,
hammering, sieving, displacing). This diversity is especially
demanded by the classes from 2t to 12t weight that have a
market share of more than 60%. Up to now this demand
has led to a wide range of technical solutions for wheel
loaders, compact-, front-, telescope- or swivel loaders and
tools with integrated prismatic or revolute module. The
HEXAPOD has been developed in addition to or rather as a
replacement for these solutions, since it is able to move the
tool (e.g. loading shovel, pallet-fork, milling head, hammer)
using the full capacity of all 6 degrees of freedom in relation
to the machine. With this manipulator the wheel loader
can tilt, lift and telescope a loading shovel without moving,
put down a pallet whilst reaching over an obstacle or push
bulk material forward with a laterally displaced tool. As a
result many different new ranges of application emerge,
which increases the practical value and the advantage in
competition for wheel loaders.

equivalent working load, lifting and dumping


characteristics as the standardized machine with 7
axis-K-Kinematics for the equipment movement in
Tz and Ry,
increase of the practical value due to new
functions as a result of additional and superposed
movement / motion in Tx, Ty, Rx and Rz,
providing the preconditions for automation and
operator assistance modules,
high stiffness of the framework, reduction of the
net weight, increase of process power and speed
of manipulation and improvement of the operator`s
sight,
energy efficiency due to improved technological
performance and lightweight design,
increase of practical value in return for higher
manufacturing costs.

The HEXAPOD parallel kinematics represents a


framework of hydraulic cylinders. Because of its nonlinear
coupled transfer characteristics a special motion control
and an ergonomic control unit is required. Those provide at
the same time the basis for valuable assistance applications
such as automation of recurring manipulations, processing
information about the working space, compensation of
inclination and spatial damping.
Another advantage is the modularity. Whenever a
customer intends to use less than 6 degrees of freedom
the hydraulic cylinders can be replaced by rods. This kind
of framework is particularly rigid; it reduces the net weight
and improves the operators sight.
By adding the modifications to a WEIDEMANN 3070CX
wheel loader the following targeted research goals were
accomplished:

Issue 01 | 2013

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NEWS & REPORTS

bauma Innovation AWARD 2013:

Catego

ry Res

earch

Technical University of Kaiserslautern - Computer


tomography enables orientation analysis of steel fibers
in reinforced concrete

raunhofer Institute for Industrial Mathematics and Institute of concrete structures and
structural engineering at TU Kaiserslautern team up as one of three nominees in the category
Research in this years Bauma Innovation Award competition.

A look inside computer tomography


enables orientation analysis of steel fibers
in reinforced concrete
The nomination is based on pioneering work on steel
fiber reinforced concrete (SFRC) that is expected to
dramatically raise the acceptance of this material in the
building industry. The increased use of steel fiber concrete
offers great potentials in terms of time-savings and costefficiencies, in addition to being an environmentally friendly
construction method. Some typical applications are
composite slabs, load-bearing floors and walls, industrial
floors, steel fiber reinforced shotcrete, segments for tunnel
construction, and underwater slabs. A production method
of uniform steel fiber reinforced concrete under building
site conditions has remained a mystery. Established
testing methods (wash-out, electro-magnetic, and photooptic systems) provide information at great expense
about the volume fraction of fiber. However, none of these
have offered a reliable and verifiable analysis of the fiber
distribution and direction.

construction where steel fiber reinforced tunnel segments


have been economically used after the fibers preferential
direction was verified absolutely as being parallel to the
border of the formwork. Currently, the focus of effort is
on fiber tomographics in stress cracks with the aim of
acquiring an improved understanding of load bearing
capabilities. The safe application of steel fiber reinforced
concrete offers many new perspectives to the entire
building industry.

Help has now arrived in the form of the algorithms


developed at Fraunhofer ITWM, which form the basis
of MAVI software. The engineers have succeeded in
implementing the worlds first descriptive testing of the
fibers according to their positioning in space, projected
length, and diameter. This news has been greeted with
great national and international interest. The Institute
of concrete structures and structural engineering at TU
Kaiserslautern has implemented this new development
for scientific testing of norms and for the study of the
post-cracking behaviour of SFRC. The testing method is
now ready for use in the assessment of damage claims
and quality monitoring. An example is provided by tunnel
FOR MORE INFORMATION AND CONTACT:
Fraunhofer-Institut fr Techno- und Wirtschaftsmathematik ITWM
Fraunhofer-Platz 1 | D-67663 Kaiserslautern
Telefon: +49 631 316 00-4674
eMail: presse@itwm.fraunhofer.de

Issue 01 | 2013

TU Kaiserslautern | FB Bauingenieurwesen
Paul-Ehrlich-Strae | D-67663 Kaiserslautern
Telefon: +49 631 205-2157
eMail: juergen.schnell@bauing.uni-kl.de

www.advanced-mining.com

184

NEWS & REPORTS

bauma Innovation AWARD 2013:

Catego

World Premiere at the 2013 Bauma:


Liebherr L 506 C and L 508 C Compact Loaders

ry Des

ign

he Liebherr Compact Loaders on display at the 2013 Bauma represent an entirely new
machine concept. The L 506 C und L 508 C combine high performance with maximum safety
and extreme versatility on all kinds of task. Both models are exceptionally low in height, at less
than 2,500 mm. The L 508 C with its 49 kW (67 hp) engine is the only compact loader with centrepivot steering in this performance category to have such a low overall height.
The excellent versatility of these models opens up
many additional applications, for example in road building,
drainage, forestry and agriculture and in the service of
local authorities and communities. The frequent changes
of operator and workplace constraints associated with
such operating tasks present no problems.
The new Liebherr Compact Loaders are an addition to
the existing range of stereo, medium-size and large wheel
loaders.

An excellent all-round view and


straightforward controls
The drivers cab is comfortably equipped, with an aboveaverage window area. The operator of the Compact Loader
has an unobstructed view of the power
tools or working attachments, and the
well-positioned rear and side mirrors
for good all-round visibility. The conicalpattern lifting gear improves visibility
even further; the driver can react
quickly to any situation arising close to
the machine. This guarantees maximum
possible protection for people in the
vicinity, the equipment and the load.

Excellent weight distribution for optimal


productivity
The Compact Loaders reduced height automatically
lowers its centre of gravity. Its tipping load limit and stability,
even on uneven surfaces, are higher. The well-matched
relationship between operating weight and tipping load is
another productivity bonus for these machines. For optimal
force distribution, the lifting cylinder is centrally located on
the tapered lift arm.
Accurate parallel movement of the working equipment
is the key to exceptionally fast and precise work: loads are
positioned and lifted reliably without manual correction or
loss of material. If a fork is fitted, a payload of more than
two tonnes is available.

The controls in the operators


cab are ergonomically laid out for
intuitively correct operation; they can
be individually adjusted by the operator
for reduced fatigue and maximum
performance. This ease of operation
enhances both productivity and safety.
The Compact Loaders operator can
concentrate fully on the task in hand
and devote full attention to working and
manoeuvring movements.

Issue 01 | 2013

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185

NEWS & REPORTS


High mobility rapid readiness for work
Thanks to the low headroom it needs, the Liebherr
Compact Loader can easily reach its working location
even if access is restricted by tunnels or underpasses. It
can also be carried without difficulty on tipper vehicles)
or in a high-cube container. If moved on a conventional
transport vehicle, the maximum height does not exceed
four meters. Mobility is enhanced by the machines
lightweight construction, which in normal circumstances
does not exceed the statutory weight limit.
A big range of ex-factory add-on options is available to
equip the Compact Loaders for a variety of different tasks.
With the easily operated quick coupler, add-on attachments
can be installed and removed rapidly and effortlessly.

High-performance equipment, easy


maintenance
The L 506 C Compact Loader weighs only 5,180 kilograms
and has a tipping load of 3,450 kg. It has a standard 0.8 m
bucket and is powered by a 45 kW (61 hp) diesel engine.
With a operating weight of 5,600 kilograms, the L 508
C Compact Loader has a tipping load of 3,850 kg. It has a
1.0 m standard bucket and a 49 kW (67 hp) diesel engine.
Easy access to all maintenance points and radiators/oil
coolers is another factor that boosts the productivity of the
new Liebherr Compact Loaders.

FOR MORE INFORMATION AND CONTACT:


Liebherr-Werk Bischofshofen GmbH
Maria Graffius
Tel.: +43(0) 50809 11-543
Fax: +43(0) 50809 17-741
eMail: Maria.Graffius@Liebherr.com
Internet: www.Liebherr.com

Issue 01 | 2013

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186

NEWS & REPORTS

bauma Innovation AWARD 2013:

Category Design

KAISER AG Fahrzeugwerk - Kaiser Walking Mobile Excavator


Innovative design, ergonomics and driver comfort are the hallmarks of the latest
generation of walking mobile excavators from KAISER.

he innovative design of KAISERs new S-Line cannot fail to impress. Rounded bodywork,
enhanced ergonomics and optimised optional equipment not only create visual harmony but
also ensure a significant increase in driver comfort.

Perfectly formed
The new generation of walking mobile excavators
reveals a consistent focus on dynamic and at the same
time functional design of every element of the vehicle
whether its the cab interior, the field of vision inside and
out of the cab or the positioning of the heating and airconditioning system. The cab and superstructure form a
single unit which in turn harmonises with the vehicle as
a whole. The new design is based on the principle of a
compact radius excavator, offering outstanding all-round
visibility of the entire working zone. The driver has a direct
view of each of the excavators pads from the cab.
Integration of the new, significantly more powerful drive
and cooling system called for innovative technological
concepts and presented a major challenge in the design
phase. When it came to developing and designing the

Issue 01 | 2013

new walking mobile excavators, KAISER benefited from


the excellent collaboration between its own development
team and established industrial designers from the firm
Design Department based in Linz, Austria.

Design meets performance


The large, dynamically designed air suction and exhaust
vents provide an immediate clue to the performance
class of the new S-Line. The new models are equipped
with the powerful COM IIIB engine which already meets
future requirements of the EU vehicle emissions standard.
Thanks to their lower centre of gravity, the new vehicles in
the KAISER S-Line boast even greater stability on extreme
slopes.

www.advanced-mining.com

187

NEWS & REPORTS


Emphasis on driver comfort
Walking mobile excavators are built for deployment in
arduous and inaccessible terrain. The driver commonly
spends more time on the job compared with other
construction sites. For that reason the cab has been
specially conceived with the needs of the user in mind. The
ergonomic layout of the extensive range of functions has
been chosen to greatly facilitate the work of the driver.
Convenient operation is just as important as a
comfortable seated position. Enhanced operator comfort
was a major focus for the S-Line, the aim being to achieve a
measurable increase in productivity on long working days.
The complexity (number of different functions) of operating
a walking mobile excavator should not be underestimated;
it is comparable to flying a helicopter and requires full
concentration at all times.
New joysticks make for easier operation of the many
hydraulic adjustment facilities and a wide range of
attachments. While the rotary button and switches are
readily accessible in the side panel, the standard display
on this series is optimally located within the drivers field of
vision and is intuitive to use.

Issue 01 | 2013

Various fresh air vents ensure a pleasant climate inside


the vehicle. Optional extras such as air-conditioning,
storage compartments for documents and provisions,
cooled bottle holder and hands-free docking station for a
mobile phone provide even greater operator comfort in the
new excavators.

Carefully chosen colour scheme


The colour scheme has been revised for this new
generation. A combination of grey and black tones
ensures a tranquil atmosphere inside the cab. The
exterior is dominated not only by the familiar KAISER blue
and yellow but also by the new anthracite finish for the
undercarriage.

FOR MORE INFORMATION AND CONTACT:


KAISER AG Fahrzeugwerk
Vorarlbergerstrasse 220
FL-9486 Schaanwald
Tel. +423 377 21 21
Fax +423 377 21 10
eMail: kaiserag@kaiser.li
Internet: www.kaiser.li

www.advanced-mining.com

188

NEWS & REPORTS

bauma Innovation AWARD 2013:

Catego

ry Des

Wacker Neuson Vertrieb Europa GmbH & Co. KG -

ign

A revolution in the demolition breaker segment: Wacker Neusons EH 100

n extremely high demolition performance with a single stroke impact energy of 100 Joule
combined with a good power to weight ratio these are the facts which are readily available
at this point in time regarding Wacker Neusons new demolition breaker. Its name: EH 100.

The new demolition breaker segment:


Wacker Neusons EH 100
Wacker Neusons new demolition breaker, a worlds first
within the range of demolition breaker, will be introduced
to the market punctually for the Bauma 2013. Powerful,
formidable and unique is how Dennis Vitze, Product
Manager for Demolition Technology at Wacker Neuson,
describes the new demolition breaker. Our idea was to
move into a higher performance class in the demolition
segment with our new demolition breaker, while remaining
easy to transport and cost efficient. This goal has been
definitively achieved with the EH 100.

The results are remarkable: On the one hand an extremely


powerful demolition breaker in a high performance class,
on the other hand a tool easy to operate, transportable and
cost-efficient thanks to its ergonomic design and the many
proven technical details coming from Wacker Neuson.
The building world can thus await with interest a
revolution within the demolition breaker segment. Let us
look forward to a demolition breaker of a new dimension
with a high degree of application flexibility and lots of
power under the hood.

The single stroke impact energy of 100 Joules is packed


into a compact hood with an absolutely new design. The
ergonomically shaped, fully spring-mounted hood allows
the operator to precisely guide the demolition breaker while
maintaining visual contact with the chisels tip. This helps
to make the demolition application extremely efficient. Plus
all this is bolstered by the low hand/arm vibrations (HAV)
of 5.8 m/s.
Wacker Neusons proven hollow piston percussion
system with striker rod is also in operation in the EH 100
and does so without wear-prone seals and gaskets. The
system also makes possible the extremely high demolition
performance. Also well-known from other electric
demolition breaker by Wacker Neuson is the wear-free
asynchronous motor with its brushless drive. It goes
without saying that both percussion system and motor are
precisely adjusted for the EH 100.

FOR MORE INFORMATION AND CONTACT:


Wacker Neuson Vertrieb Europa GmbH & Co. KG
Silke Mller, Corporate Public Relations
Preuenstrae 41 | D-80809 Mnchen
Tel. +49 - (0)89 - 354 02 383
eMail: Silke.mueller@wackerneuson.com
Internet: www.wackerneuson.com

Issue 01 | 2013

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189

ADVERTISMENT

NEWS & REPORTS

Issue 01 | 2013

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190

EVENTS

2013

THE AMS-EVENT CALENDER


April 2013
01 Apr 6th Coaltrans Brazil

Rio de Janeiro, Brazil

www.coaltrans.com

03 - 05 Apr IMade in Steel 2013

Milan, Italia

www.madeinsteel.it

08 - 09 Apr Hunter Valley Coal Chain Conference 2013

New South Wales, Australia

www.ausimm.com.au

08 - 10 Apr CRU 12th World Copper Conference

Santiago, Chile

www.crugroup.com

08 - 12 Apr Hannover Messe 2013

Hanover, Germany

www.messe.de

10 - 10 Apr 5th Annual Saskatchewan Mining Supply Chain Forum

Saskatoon, Canada

www.enterprisesaskatchewan.ca

11 - 11 Apr Mining, Energy and Water Summit 2013

Santiago, Chile

www.crugroup.com/events/miningandenergy

11 - 13 Apr IAC Third Annual Gold Conference 2013

New York, USA

www.acteva.com

12 - 13 Apr Weiterbildung MINING

Aachen, Germany

www.advanced-mining.com/academy

14 - 14 Apr Gold and Precious Metals Day

London, UK

www.mining-journal.com

15 - 16 Apr

Johannesburg, South Africa

www.psrcentre.org

Chanty-Mansijsk, Russia

www.rohstoff-forum.org

International Conference on Mining, Mineral Processing and Metallurgical Engineering 2013

15 - 17 Apr 6. Rohstoff-Konferenz
15 - 17 Apr MineWater Solutions in Extreme Environments 2013

Lima, Peru

www.infomine.com

15 - 21 Apr bauma 2013

Mnchen, Germany

www.bauma.de

16 - 19 Apr 23. International Mining Congress and Exhibition of Turkey

Antalya, Turkey

www.imcet.org.tr

16 - 17 Apr Global Exploration, Mining and Minerals (GEMM) 2013

Vancouver, Canada

www.beedie.sfu.ca/rmsi/gemm2013

16 - 17 Apr Botswana Coal and Energy Conference

Gaborone, Botswana

www.immevents.com/botswanacoal

16 - 18 Apr The European Gold Forum 2013

Zurich, Schwitzerland

www.europeangoldforum.org/egf13

19 - 20 Apr Mongolia Mining Expo 2013

Ulaanbaatar, Mongolia

www.mongolia-mining.org

22 - 25 Apr 2013 World of Coal Ash Conference WOCA

Lexington, USA

www.worldofcoalash.org

23 - 25 Apr PARTEC 2013

Nrnberg, Germany

www.nuernbergmesse.de

24 - 25 Apr Canadian Mining and Industrial Expo 2013

Sudbury, Canada

www.dacshows.com

24 - 26 Apr Minerals North Conference 2013

Terrace, Canada

www.mineralsnorth.ca/future-conferences

25 Apr REWIMET-Symposium

Goslar, Germany

www.rewimet.de

25. Mai Zukunftstag im Geozentrum Hannover

Hanover, Germany

www.bgr.bund.de

London, UK

www.mining-in-a-day.com

26 - 26 Apr Mining in a Day London 2013


29 - 29 -Apr Coal Fundamentals

Sydney, Australia

www.iired.com.au/training

Brisbane, Australia

www.drillandblastevent.com.au

30 Apr - 02 May Africa Mining Australia 2013

Perth, Australia

www.beaconevents.com/2013/AfricaMiningAustralia2013

09 Apr - 02 May Annual Coal Processing Exhibition and Conference Coal Prep 2013

Lexington, USA

www.coalprepshow.com

30 Apr- 01 May Drill and Blast 2013

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EVENTS

2013

THE AMS-EVENT CALENDER


May 2013
05 - 08 May CIM Conference and Exhibition 2013

Toronto, Canada

www.web.cim.org/toronto2013

05 - 08 May Planetary and Terrestrial Mining Sciences Symposium

Toronto, Canada

www.ptmss.com

06 - 08 May Intertech 2013

Baltimore, USA

www.intertechconference.com

07 -09 May ARMINERA 2013 IX International Mining Exhibition

Buenos Aires, Argentinia

www.arminera.com.ar

07 - 08 May sterreichischer Bergbautag 2013 Mobilitt in der Mineralrohstoffindustrie

Seggauberg, Austria

www.bvo.at

08 - 09 May Open Pit Slope Design and Implementation

Vancouver, BC, Canada

www.edumine.com

09 - 10 May Uganda and COMESA Oil, Gas and Mining Summit 2013

Kampala, Uganda

www.comesaogm.com

11 - 12 May 5. Gttinger Energietagung

Gttingen, Germany

www.efzn.de

11 - 12 May Geominetech 13th Annual Symposium

Bhubaneswar, India

www.geominetech.webs.com

12 - 16 May Clean Coal Technologies Conference (CCT) 2013

Thessaloniki, Greece

www.iea-coal.org.uk

12 - 16 May 2nd International Conference on Materials for Energy (EnMat II)

Karlsruhe, Germany

www.dechema.de

13 - 14 May The Metals and Minerals Investment Conference New York 2013

New York, USA

www.metalsandmineralsevents.com

14 - 15 May IHS McCloskey European Coal Outlook Conference 2013

Nice, France

www.ihs.com/events

14 - 16 May Miningworld Russia 2013

Moscow, Russia

www.miningworld-russia.primexpo.ru

15 - 16 May Bulk Handling Conference

North Lincolnshire, UK

www.bulk-online.com

15 - 16 May 4th Annual Metals Trading Operations & Technology Summit 2013

London, UK

www.mtotsummit.com

15 - 17 May 9th International Geothermal Conference IGC 2013

Freiburg, Germany

www.geothermiekonferenz.de

19 - 22 May 2013 Haulage and Loading Conference

Phoenix, USA

www.haulageandloading.com

20 - 21 May The Mining for Development Conference 2013

Sydney, Australia

www.im4dc.org

20 - 24 May Mining Agreements

St Andrews, UK

www.dundee.ac.uk

21 - 22 May 3rd Sino-German Conference & Excursions. Underground storage of CO2 and energy

Goslar, Germany

www.efzn.de

21 - 24 May Expomin China 2013

Beijing, China

www.expominchina.com

22 - 23 May AACHEN INTERNATIONAL MINING SYMPOSIA - AIMS 2013

Aachen, Germany

www.aims.rwth-aachen.de

22 - 24 May Ground Improvement and Support in Underground Construction and Mining

Golden, USA

www.csmspace.com/events

26 - 29 May Mining and Quarrying Oman 2013

Muscat, Oman

www.miningandquarryingoman.com

27 - 27 May ICEGS - Internatinal Conference on Enhanced Geothermal Systems

Potsdam, Germany

www.icegs.eu

27 - 28 May Advanced Crushing and Grinding Techniques

Lima, Peru

www.edumine.com/courses

27 - 28 May Groundwater Modelling for Mining

Lima, Peru

www.edumine.com/courses

29 - 30 May Rock Mass Characterization for Mine Design

Lima, Peru

www.edumine.com/courses

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EVENTS

2013

THE AMS-EVENT CALENDER


May 2013
28 - 30 May UMEC Uganda Mining and Energy Conference and Exhibition 2013

Kampala, Uganda

www.umec-uganda.com

31 May - 01 Jun Open Pit Slope Design

Lima, Peru

www.edumine.com/courses/short-courses

31 May - 07 Jun ITA AITES World Tunnel Congress WTC 2013

Geneva, Schwitzerland

www.wtc2013.ch

11 - 14 Jun 5. Internationale Tagung MBA und Sortieranlagen (Waste-to-Resources 2013)

Hanover, Germany

www.waste-to-resources.eu

12 - 14 Jun GDMB-Fachausschuss Geothermie

Bochum, Germany

www.gdmb.de

12 - 13 Jun 4. URBAN MINING Kongress

Iserlohn, Germany

www.urban-mining-kongress.de

June 2013

12 - 14 Jun Ghana Mining Summit 2013

Accra, Ghana

www.ghanaminingsummit.org

12 - 16 Jun XV Balkan Mineral Processing Congress 2013

Sozopol, Bulgaria

www.bmpc2013.com

18 - 19 Jun The Turkey Mining Show 2013

Istanbul, Turkey

www.terrapinn.com/exhibition

20 - 21 Jun 12. BergbauForum

Leipzig, Germany

www.bergbauforum.de

20 - 21 Jun International Gold Mining Conference 2013

Zhaoyuan City, China

www.goldminingconference.com

23 - 26 Jun European Metallurgical Conference Emc2013

Weimar, Germany

www.emc.gdmb.de

Milos Island, Greece

www.sdimi2013.conferences.gr

Hanover, Germany

www.hannovermesse.de

Munich, Germany

www.bauma.de

09 - 10 May GeoBioEnergie 2012 im Rahmen der IFAT ENTSORGA

Munich, Germany

www.enerchange.de

15 - 16 May Bulk Handling Conference (Bulk2013)

North Lincolnshire, UK

www.bulk-online.com

Freiburg, Germany

www.enerchange.de

Aachen, Germany

www.aims.rwth-aachen.de

Freiburg, Germany

www.enerchange.de

12 - 13 Jun 4. URBAN MINING Kongress

Iserlohn, Germany

www.urban-mining-kongress.de

12 - 14 Jun GDMB-Fachausschuss Geothermie

Bochum, Germany

www.gdmb.de

30 Jun - 03 Jul SDIMI 2013 Sustainable Development in the Minerals Industry Conference
Event-Highlights 2013
08 - 12 Apr Hannover Messe

15 - 21 Apr bauma 2013


15 - 17 May 9th International Geothermal Conference IGC 2013
International Mining Symposia (AIMS 2013)
22 - 23 May Aachen
Mineral Resources and Mine Development
27 May ICEGS 2013 - 2nd International EGS-Conference

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193

EVENTS

Special-Event

Der mobile Schrott- und Metallplatz

www.recycling-aktiv.com
ADVERTISEMENT

Fax-Anfrage +49 7229 606-39


Tel. +49 7229 606-30
info@geoplanGmbH.de

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EVENTS

Issue 01 | 2013

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195

EVENTS

Issue 01 | 2013

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196

Company-Presentation
NEWS & REPORTS

Mining Technology Consulting


Field of activity
Feasibility studies

equipment selection

Exploration

drilling & blasting

geological modelling

slope stability & monitoring

geostatistical resource estimation

assessment of geotechnical risk

resource classification

hydrological investigation

mine design

health & safety in mining

mine optimization

Geological Investigation
Exploration
Survey & Mapping
Mineral exploration program
Geological investigation
Geochemical investigation
Geological and structural analysis
Microscopic investigation and mineralogical analysis

Geological Modelling
Data collection and review of projects
Database validation and verification
Exploration and data management
3D geological, structural and mineralization interpretation
and modeling
Statistic and geostatistic analysis
Geostatistical resource estimation
Resource classification, reporting andreconciliations

Mine Design & Mine Optimization


Mine Planning
Design and optimization of pit layout
Mine development planning
Scheduling
Design of mine dumps
Optimum location of surface facilities

Issue 01 | 2013

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197

Company-Presentation
NEWS & REPORTS
Equipment Selection & Modelling
Loading and haulage
Transport route optimization
Optimization of primary crusher location (Mobile / semimobile / stationary crusher)
Economic evaluation

Slope Stability & Monitoring


Geotechnical investigation
Groundwater investigation
Slope stability assessment
Slope design
Implementation of geotechnical instrumentation
Slope monitoring
Assessment and management of geotechnical risks

Drilling & Blasting


Planning of drilling and blasting
Blast vibration control
Control of borehole deviation
Economic evaluation

Compact courses
For the international mining industry on mining methods
and technology:
Seminars, conferences, courses, lectures and workshops

FOR MORE INFORMATION AND CONTACT:

Mining Technology Consulting


Professor Dr.-Ing. habil. H. Tudeshki

Albrecht-von-Groddeck-Str. 3
D-38678 Clausthal-Zellerfeld

Tel.: +49(0) 53 23 - 98 39 33
Fax: +49(0) 53 23 - 96 29 90 8

www.mtc-tudeshki.com

Issue 01 | 2013

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198

Presentation
NEUHEITEN
of new
& REPORTAGEN
products

Mining Calculator:
A Software for Mine Optimization
Software characteristics





Individual equipment selection for loading and haulage


Discontinuous and continuous haulage systems
Equipment matching
Economic analysis
Ecological assessment (greenhouse gas emissions)
Overall-comparison and rating of different bulk material
handling systems as a basis for key decisions
Improvement of economic and ecological feasibility

Key applications



Feasibility studies for green and brown field projects


Optimization of operating mines and earthmoving projects
Evaluation of project development dynamics
Education

Key functions




Selection of loading and haulage systems


Equipment matching
Calculation of various cost types
Determination of CO2-emissions
Presentation of results by tables and diagrams

Mining Technology Consulting


Albrecht-von-Groddeck-Str. 3
38678 Clausthal-Zellerfeld | Germany
XGraphic Ingenieurgesellschaft mbH
Aretzstr. 9
52070 Aachen | Germany

Ausgabe 01 | 2013

Information and contact:


Internet: www.mining-calculator.com
eMail: info@mining-calculator.com

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IMPRINT
PUBLISHING COMPANY

AMS Online GmbH


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eMail: redaktion@advanced-mining.com
Internet: www.advanced-mining.com
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EXECUTIVE MANAGER

Dipl.-Umweltwiss. Christian Thometzek

PUBLISHER

Prof. Dr.-Ing. habil. Hossein H. Tudeshki


University Professor for Surface Mining and
International Mining
eMail: tudeshki@advanced-mining.com

EDITORIAL TEAM

Prof. Dr.-Ing. habil. Hossein H. Tudeshki


Dr. Monire Bassir
Dipl.-Umweltwiss. Christian Thometzek
eMail: redaktion@advanced-mining.com

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Dipl.-Umweltwiss. Christian Thometzek


eMail: Christian.thometzek@advanced-mining.com

BANK CONNECTION

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GRAPHICAL DESIGN

Graumann Design
Dipl.-Des. Kerstin Graumann
Mildestieg 13
22307 Hamburg | Germany
Tel.: +49 (0) 40 - 741 061 64
eMail: kontakt@graumann-design.de
Internet: www.graumann-design.de

PROGRAMMING INTERNET SITE

79pixel
Steffen Ottow, B.Sc.
Bodestrae 9
38667 Bad Harzburg | Germany
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eMail: steffen@79pixel.de
Internet: www.79pixel.de

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CONTENTS

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Issue 01 | 2013

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