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Flender gears secure plant availability in Australia’s fourth biggest mine

Flender gears secure plant availability in Australia’s fourth biggest mine

Dalian Huarui Heavy Industry Group Co., Ltd (DHHI) is a Chinese technology and industry company active in a diverse range of fields. One of these is hoisting machinery. To enable it to supply the Roy Hill Mine in Australia with technical equipment as part of a large-scale project “Roy Hill Iron Ore”, DHHI is working in cooperation with Siemens. By choosing solutions from the Flender portfolio, DHHI is benefiting from lightweight energy-efficient drives which not only offer outstanding availability but also require minimal maintenance.

The Roy Hill iron ore mine in Australia is the country’s fourth biggest mine with an annual output of around 55 million tons. The Chinese technology company Dalian Huarui Heavy Industry Group Co., Ltd (DHHI), whose fields of activity include hoisting machinery, was commissioned in 2015 to fit the mine with new technical equipment. The extremely high yield of iron ore from the mine and the scope of the transportation solutions required made this one of the biggest projects of its kind anywhere in the world. DHHI opted to bring a strong partner on board to execute the contract in the form of Siemens and the Flender portfolio, which played an instrumental role in the successful implementation of the project.

Outstanding efficiency

The conveyor systems used in the mine have to be capable of transporting around 14,400 tons of bulk cargo – substantially more than previously. To fulfill this tough remit, the main drive systems used in the total of seven bucket-wheel stacker-reclaimer units, the ship loader and the double cabin tippler system at Roy Hill were sourced from Siemens. The same applies to the drives for the conveyor system. Siemens also supplied the engineering expertise, which includes the selection of the couplings and drives according to customer requirements over the construction up to the organization on-site. The products used, part of the Flender portfolio, are specially designed for use in high-performance applications and enable energy-efficient, low-maintenance plant operation with outstanding availability. Siemens provided the master drive systems for DHHI’s two bucket-wheel stacker-reclaimers (14,400 tons per hour), one ship loader (12,500 tons/hour), five other types of tackerreclaimers, and one double-cabin tippler system. In addition, Flender also supplied drive systems for the bulk cargo transportation equipment. Engineering services were also part of the package. In this concrete application, the Flender gear units for bucket wheel excavators provide an output of 2,600 kilonewton meters (kN m). The relatively low intrinsic weight of the gears means that only a similarly light counterweight is required at the other end of the boom. This simplifies the entire process of handling the equipment and also reduces its energy requirement. Reduced weight also minimizes the risk of the boom becoming deformed, which in turn increases the availability of the overall plant.

Low maintenance and a long life

High plant availability is a factor of particular importance in Australia due to the high costs of maintenance. In addition, Australia’s rigorous reliability standards mean that all machines used have to achieve 95 percent operational reliability, with the remaining five percent set aside as a maintenance reserve. The Siemens solution, which is designed to achieve a service life of around 30 years, enables maintenance to be carried out during running operation. Wang Peng, Director of the DHHI Design Institute for Bulk Cargo Machinery, said: “By cooperating with Siemens, DHHI was able to win this big order.” The success of this project has paved the way for Siemens and DHHI to work closely together on future cooperation projects.

Source: Siemens Flender

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