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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 drivesystems used in the total of sevenbucket-wheel stacker-reclaimer units,the ship loader and the double cabintippler system at Roy Hill were sourcedfrom Siemens. The same applies tothe drives for the conveyor system.Siemens also supplied the engineeringexpertise, which includes the selectionof the couplings and drives accordingto customer requirements over the constructionup to the organization on-site.The products used, part of the Flenderportfolio, are specially designed for usein high-performance applications andenable energy-efficient, low-maintenanceplant operation with outstandingavailability. Siemens provided the masterdrive systems for DHHI’s two bucket-wheel stacker-reclaimers (14,400tons per hour), one ship loader (12,500tons/hour), five other types of stackerreclaimers,and one double-cabin tipplersystem. In addition, Flender alsosupplied drive systems for the bulkcargo transportation equipment. Engineeringservices were also part of thepackage. In this concrete application,the Flender gear units for bucketwheel excavators provide an outputof 2,600 kilonewton meters (kN m).The relatively low intrinsic weight ofthe gears means that only a similarlylight counterweight is required at theother end of the boom. This simplifiesthe entire process of handling theequipment and also reduces its energyrequirement. Reduced weight alsominimizes the risk of the boom becomingdeformed, which in turn increasesthe availability of the overallplant.

Low maintenance and a long life

High plant availability is a factor ofparticular importance in Australia dueto the high costs of maintenance. Inaddition, Australia’s rigorous reliabilitystandards mean that all machinesused have to achieve 95 percentoperationalreliability, with the remainingfive percent set aside as a maintenancereserve. The Siemens solution,which is designed to achieve a servicelife of around 30 years, enables maintenanceto be carried out during runningoperation. Wang Peng, Directorof the DHHI Design Institute for BulkCargo Machinery, said: “By cooperatingwith Siemens, DHHI was able towin this big order.” The success ofthis project has paved the way forSiemens and DHHI to work closely togetheron future cooperation projects.

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Source: Siemens Flender

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