Fórum de Soluções e

Novas Tecnologias para Engenharia

Bulk Materials Handling
Diretoria de Gestão de Projetos de Capital
Área de Suporte à Engenharia

Belo Horizonte, 22 de Julho de 2014

SANDVIK MGS

Rui Camara - Gerente de Engenharia

 Success stories
Over 350 Material Handling machines delivered all over the world
Supply of the world’s largest compact bucket wheel excavator 2009 Hungary
Over 400 km of conveyors installed

2 Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Success stories
>35% of the global seaborne iron ore is loaded with Sandvik shiploaders

• World´s biggest shiploaders in Brazil with a capacity of 20.000 tph iron in

operation since 2013

3 Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
Solução de Engenharia Nº 1
Gearless Drives

SANDVIK MGS
 Conveyor Systems in Mining
Current and future requirements

Capacity > 20.000 tph

Particle size up to 450 to 600 mm

Belt width up to 3.000 mm

Belt speed > 7 m/s

New conveyor drives (>3,5MW with bevel helical gearbox) up to 10 MW

Increased belt breaking strength ST 10.000

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Direct Drives (gearless) for Conveyor Systems
Design figures and key factors

• Long distance, eg overland conveyors

• Conveyors with inclination

Gearbox

Coupling
Coupling

Brake
VFC
Induction Drive
• High capacities Motor Pulley
(> min. 3000 tph - ball park figure)
• Min. drive power: 2,5-3 MW per drive
• Drive power can be divided
in favour of direct drives
(eg 2x3 MW instead of 4x1,5 MW etc.)
• Remote areas with "bad" site
accessibility for maintenance
• In general mines with high OPEX

Brake
VFC
Induction Drive
Motor Pulley

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Direct Drives Flange Connection
Sandvik/GE design – 3D-Model

Motor (Stator+Rotor)

Slider Plates

Pulley Frame

Drive Pulley
Disc Brake

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Conveyor Drive Station with Direct Drive
Existing motor sizes for required power levels

Motor (Stator)

Slider Plates Motor (Rotor)

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Conveyor Drive Station with Direct Drive
3d Models – Different Views

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Direct Drives (Gearless) for Conveyor Systems
Assumptions – reference case for calculation

Material Copper ore; 1,8 t/m³

Capacity 12.000 tph
Belt speed 7 m/s
Conveyor length 5.000 m
Elevation 140 m
Installed drive
4 x 2.500 kW
power (geared)
Installed drive
2 x 5.000 kW
power (direct)

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Comparison Geared vs. Direct Drive
Simplified layout of drive station

Geared Drive Direct Drive

Bearing

4 x 2500kW
1000rpm motor

Coupling

2 x 5000kW
18:1 Gearbox
55rpm overhung motor

Bearing
Drive pulley Drive pulley

4 motors 2 motors
4 gearboxes 0 gearboxes
8 couplings 0 couplings
44 bearings 4 bearings

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Comparison Geared vs. Direct Drive
Simplified layout of drive station

Geared Drive Direct Drive (only 1 motor shown)

Power supply for geared drives: Power supply for direct drives:

•4 x MV AC Inverters •2 x MV AC Inverters

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Comparison Geared vs. Direct Drive
Additional issues to consider (1) – What else will change?

• Belt rating (optional): if the conveyor system can be simplified by reducing

the number of drive pulleys, the belt tension will rise due to lower wrapping
angle (“Eytelwein equation”).
This can lead to higher belt classes as downside.  Cost management!

• Pulleys: higher belt ratings and new belt categories (ST10.000) will require
pulley diameters of 2,5 m or more

Geared Drive Direct Drive

2 x 1.500 kW
1 x 6.000 kW
2 x 1.500 kW

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Comparison Geared vs. Direct Drive
Additional issues to consider (2) – What else will change?

• Brakes: low speed disc brakes (spring-released) applied only

• Foundation: smaller footprint of drive stations expected (less components),

but higher ground bearing pressure of motors leads eventually to thicker
reinforced base plates

• E-House: Simplified layout and smaller dimensions of E-house due to lower

amount of drives (2 instead of 4)

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Impacts in Technical Specification
SPE VALE

Due to this new drive technology, there are some impacts in VALE’s belt
conveyor specification (ET-M-406_R08) that needs to be discussed and
updated:

•Item 4.0: This item includes some mandatory drive components, like
gearboxes but in this case is not aplicable;
•Item 5.3.8: This item must be adjusted, because the concept of base drive is
different;
•Item 6.4: Drive pulley must be designed for this special case, there are some
issues that have to be considered;
•Item 6.7: Not applicable;
•Item 6.10: Brakes have to be installed directly in pulleys shaft;
•Item 8.0: This item must be adjusted to include only applicable components.

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Direct Drive Pulleys
Adapted state-of-the-art pulley design

• Heavy duty pulleys for high capacity mine conveyors

• Sandvik in-house design and fabrication up to 2.500 mm pulley diameter
• Adapted pulley shaft and pulley bearing design according to rotor overhung load
• higher shaft stiffness
• minimum shaft deflection in vertical direction
• Design principles proven in hoist installations

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Direct Drive Pulleys
Adapted state-of-the-art pulley design

• Belt tensions cause horizontal forces and pulley

deflection.
• Higher overhung loads in gearless drives stress
the pulley more vertically than in conventional.

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 CAPEX
Advantages of Direct Drives
Cost savings – Investment

Removing of gearboxes

•Fewer components have to be purchased

•Reduced spare parts inventory

More drive power per pulley

•Smaller footprint of drive station due to fewer installed components

•Longer conveyors possible by reducing amount of drive / transfer stations
(beneficial especially for drift and tunnel conveyors due to excavation
underground)
•Smaller E-houses due to fewer drives / motors

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 CAPEX
Advantages of Direct Drives
Cost savings – Investment
Smaller footprint of drive station, fewer components

Reduced spare parts inventory

Smaller footprint of E-houses, less electrical

installation
Less drive pulleys

Less drive / transfer stations, longer conveyors

$ per installed kW drive power

Foundation – smaller footprint, but higher motor

load
Higher weight of drive pulleys

Similar CAPEX than for conventional geared drives!

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 CAPEX
Advantages of Direct Drives
Cost savings – Investment

Further decrease of CAPEX for gearless conveyor drives

is going to happen, when:

•Planning of whole conveyor system in a plant is done in favor of large gearless

drives > 3 MW per motor (longer conveyors, less interfaces)!

•Price of super class belts ST10.000 and potentially higher is in a reasonable

range (market determines the demand and thus the belt price)!

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 OPEX
Advantages of Direct Drives
Cost savings – Operational cost (1)

Availability

•Higher system and plant availability due to fewer installed components

•Higher availability by less downtime due to breakdowns and maintenance
•Increased production up to 520.000 USD per hour at 12.000 tph copper ore (even more
revenue possible for iron ore at same capacity)

Maintenance

•Reduction of maintenance cost for gearboxes, couplings, bearings, additional pulleys,

motors and brakes (usually annual 5% of investment of these components);
up to 150.000 USD per year for 4 x 2.500 kW installed power.

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 OPEX
Advantages of Direct Drives
Cost savings – Operational cost (2)

Energy efficiency

•Higher drive efficiency (1,4 %) due to removed gearbox

•Cost savings up to 160.000 USD per year for 10 MW

•Regenerative Conveying:
• A conveyor with a capacity of 12.000 tph and a drop of 110 m
can generate 3,6 MWh of electrical energy in one hour

• Additional savings up to 58.000 USD per year due to + 1,4 %

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 OPEX
Advantages of Direct Drives
Cost savings – Operational cost

Higher system availability increases production

Reduced maintenance cost

Higher drive efficiency

Significantly lower OPEX than for conventional geared drives!

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Advantages of Direct Drives
Summary

• Fewer drives per conveyor with fewer and smaller drive stations and
higher power per pulley
• Longer conveyors, therefore a new approach in the planning of the plant
• Significant savings in operational cost (OPEX) of the mine
- Higher system and plant availability due to fewer mechanical and hydraulic
components;
- Reduced Maintenance due to the absence of gearboxes, fluid couplings and
bearings;
- Higher energy efficiency and savings (up to 1.600 MWh per year for 2 x
5MW drives based on 95% utilization

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
Solução de Engenharia Nº 2
Melhorias p/ Manut.de Roletes

SANDVIK MGS
 Manutenção dos Roletes sob Guia de Material
Roletes de Impacto do Tipo “Jack-Down”

Vantagens:
•menor tempo requerido para troca dos rolos sem necessidade de
desmontagem da guia de material;
•segurança na manutenção.

SPE - ET-M-406: item 6.2.3 (roletes de impacto)

Anexo1 / Anexo 2 / Anexo 3

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Manutenção dos Roletes sob Guia de Material
Roletes de Impacto e Carga c/ Suportes Laterais Articulados

Vantagens:

•facilidade de manutenção com maior rapidez na troca dos rolos;

SPE - ET-M-406: item 6.2.1 e 6.2.3 (roletes de carga e impacto)

Anexo 4

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Manutenção dos Roletes sob Guia de Material
Roletes de Impacto e Carga c/ Suportes Laterais Deslizantes

Vantagens:

•facilidade de manutenção com maior rapidez na troca dos rolos;

SPE - ET-M-406: item 6.2.1 e 6.2.3 (roletes de carga e impacto)

Anexo 5

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Manutenção dos Roletes sob Guia de Material
Dispositivo para Levantamento da Correia

Vantagens:

•construção leve;
•facilidade na elevação da correia no lado de carga/retorno;
•Maior rapidez na troca dos rolos.

Belt lifter / Catálogo 1 / Catálogo 2

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
Solução de Engenharia Nº 3
Proj. de Chutes de Descarga

SANDVIK MGS
 Análise de Chutes de Descarga
Objetivo

• evitar desalinhamento da correia;

• centralizar o fluxo de material;
• distribuir o material de modo uniforme sobre correia;
• equalizar velocidades: queda do material x transportador;
• equalizar direções de fluxo: material em queda x transportador;
• minimizar velocidade de queda do material;
• aumentar vida útil da correia.

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Análise de Chutes de Descarga
Método de Elemento Discreto (Dem-Rocky)

Premissas para Análise:

•Características Gerais: densidade real e aparente, distribuição

granulométrica, umidade;
•Características Especificas: coeficiente de restituição,
atrito estático e dinâmico, índice de coesão, forma do grão

Vantagens:

•Menor risco de entupimento;

•Menor desgaste da correia;
•Menor desgaste das chapas de desgaste (revestimento);
•Redução da geração de pó.

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
 Análise de Chutes de Descarga
Método de Elemento Discreto (DEM-Rocky)

Cálculo por DEM:

•Exemplo 1
•Exemplo 2

SPE – ET-M-406: item 6.18 (chutes de descarga)

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Sandvik Mining Systems – Fórum de Novas Tecnologias para Engenharia – Bulk Materials Handling
Dúvidas!
Muito Obrigado!

Rui Camara
SANDVIK MGS
rui.camara@sandvik.com
(11) 3616-1400 / (11) 98471-9726