ThyssenKrupp Fördertechnik GmbH

ThyssenKrupp Allee 1 · 45143 Essen · Germany

Tel.: +49 (0) 201/8 28-04

www.thyssenkrupp-foerdertechnik.com

Gea

rless

-driv

es |

e1 0

8201

1

For further information, please contact:

ThyssenKrupp Robins, Inc.6400 South Fiddler’s Green Circle, Suite 700Greenwood Village, Colorado 80111USA sales.tkri@thyssenkrupp.com www.thyssenkrupprobins.com

Siemens AG Industry Sector Industry Solutions Mining Technologies Schuhstr. 60 91052 Erlangen Germany mining@siemens.com www.siemens.com/mining

ThyssenKrupp Fördertechnik GmbHBusiness Unit MiningThyssenKrupp Allee 145143 EssenGermanyinfo@tk-mining.comwww.tk-mining.com

Belt

Conveyor

Coupling

CouplingBrake

Gear Box

Belt

Con

veyor

Brake

C-Converter

Transformer

Synch.Motor

C-Converter

Transformer

Synch.Motor

BeltDrivePulley

BeltDrivePulley

Our solution:Gearless Drives for conveyors – capable of handling high power requirements and easy to maintain

Together with Siemens, ThyssenKrupp has introduced a new high-performance generation of gearless, cycloconverter-fed conveyor drives. The principle has been proven for more than 25 years, with ongoing research and development. Its advantages are clear to see: fewer components, high availability, reduced overall energy consumption, lower maintenance costs.

Redefining power for conveyor drives

Long conveyors with high throughput and steep height differences require a significant amount of power. When the demand for power exceeds three MW per pulley, Gearless Drive systems are the right solution. This system overcomes the restrictions attributed to gear reducers, and its gearless construction is simple, robust and easy to maintain. Cycloconverter technology has proven its high reliability over several decades. Conveyor belt suppliers are also able now to manufacture stronger belts (ST-10,000) that can withstand higher stresses result-ing from higher drive power. In a word: The time to go gearless has come.

Fewer components, longer conveyor

Fewer high performance drives replacing many conventional ones: This formula makes longer conveyors more feasible and economical. With fewer components, the drive stations require smaller footprints. In underground applications, the number of expensive excavations are minimized.

Conventional drive system with fixed speed (left) and speed-

controlled Gearless Drive (right). By reducing mechanical

parts, maintenance costs can be significantly re duced: up

to 5 percent annually of the initial investment costs.

Good reasons for Gearless Drive Systems from Siemens and ThyssenKrupp |Compared to gear-reducer technology:

• Higher plant availability by eliminating electrical components, couplings, gearboxes, associated bearings and lubrication systems – therefore minimizing the risk of downtime

• Up to four percent higher energy efficiency achieved with gearless direct-drive technology

• Longer conveyors with fewer and smaller drive stations, resulting in reduced excavations in underground applications

• Higher power at the pulley – free from traditional gearbox limitations

• Reduce the potential for mechanical break-downs by using more robust components

• Fewer spare parts resulting in less inventory and lower capital investment

• Reduction of noise levels by eliminating the reducer, the loudest part of a conventional drive station In COOpERATIOn WITH SIEMEnS

Gearless Conveyor Drives Highest reliability, increased energy efficiency and low maintenance

ThyssenKrupp FördertechnikExcellence in Technology

rz_tk_GearlessDrive_brochure_USletter_GB.indd 1-3 01.09.11 10:29

The beginning: 1985 – the first conveyor using a gearless drive

In 1985, Siemens and ThyssenKrupp teamed up to install the world’s first gearless direct-drive belt conveyor with cycloconverter-fed synchronous motors. Engineers at RAG Deutsche Steinkohle were strongly persuaded by converter technology, and decided to apply it to the underground prosper-Haniel coal mine in Germany. More than a quarter-century later, the belt drives are still in operation – to the complete satisfaction of the customer. Management at RAG indicate that:

• There have been no significant interruptions or failures attributable to motors and converters

• Maintenance costs are significantly less than for belt drives with gearboxes

• Estimated savings of 10 percent on electrical energy are achieved annually compared to fixed speed geared conveyors.

The next generation: Going gearless in the peruvian Andes

Continuing their successful teamwork, ThyssenKrupp and Siemens are delivering Gearless Drives for Xstrata Copper’s new Antapaccay mine in peru. The drives will be operated at an elevation of 4,200 meters (13.780 feet). Two 3,800 kW (5,096 Hp), low-speed synchronous motors will provide 631 knm of torque to each drive pulley. The 1.37 meter wide belt will extend for 6,528 meters. The capacity of the conveyor is rated at 5,263 metric tons per hour, and it will operate at 6.2 meters per second. Using the well proven air-cooled cycloconverter will provide excellent behavior in this remote and mountainous area; specifically…

• When very high torque is needed; for example,

when restarting the conveyor at low speed

• In case one of the two drives goes down; operators then can continue using the system, empty the fully loaded belt and continue to operate the conveyor at a reduced rate.

SInAMICS SL 150 cycloconverter – air-cooled

• High overload capability

• Full converter power up to lowest motor speed (0 rpm)

• High efficiency through direct energy transformation (one step for AC/AC)

• Simple topology and few components result in: - robustness with high reliability - low investment costs - easy maintenance

• Low space requirement

• Long-established and proven converter technology

• Converter output frequency maximum 0.45 x fnet

SInAMICS SM 150 voltage source converter – water-cooled

• Latest converter technology

• Opportunity to regenerate for downhill operation and during breaking

• Excellent line impact - no reactive power is generated - low-line harmonics

• power compensation system is not needed

• Fast switching element (IGCT) results in high drive performance

• High efficiency as a result of high-voltage operation

• Converter power de-rating at very low output frequency < 2Hz

Your benefit:Move more ore. Save on energy. Save on maintenance costs.

Which converter to use?

Siemens offers two types of converters, each of which has its benefits. In Xstrata

Copper’s Antapaccay mine, the air cooled cycloconverter

SInAMICS SL 150 is used. The same converter is used for mill drives. Our engineers will

be glad to help you find the right solution for your mine.

In many mining areas, ore grades are declining. new mines are being developed in more remote areas, pits are getting deeper and underground mines are becoming larger. This means that more and more material must be transported over long distances and material handling poses new challenges. In order to achieve the increasing volumes and high demands for availability, conveying systems will need to implement the technologies made possible by today’s larger drive systems.

Can traditional drives stand up to 20,000 kW?

Drive configurations for large conveyors with gearboxes will reach their physical limits. For example a conveyor system with a drive power demand of more than 20,000 kW would require eight traditional drives, each of them equipped with 2,500 kW motors. Such a solution brings the disadvantage of reduced overall availability associated with a large number of mechanical components.

Maintenance in remote locations

The need for highly reliable equipment that can perform in remote mining regions is continually increasing. And at the same time maintenance costs need to be kept under control while production costs increase. Therefore, the need to use new technologies that reduce maintenance costs is an important factor when deciding on your future material handling solution.

You expect...

• Systems that help you transport more ore over longer distances

• High availability and minimized maintenance costs

• precise and powerful drive solutions

• Robust equipment, with fewer electrical and mechanical components

• Lower operating costs

• Optimized energy consumption

Your challenge:Remote locations, longer distances, higher throughput, difficult maintenance conditions

rz_tk_GearlessDrive_brochure_USletter_GB.indd 4-6 01.09.11 10:29

ThyssenKrupp Fördertechnik GmbH

ThyssenKrupp Allee 1 · 45143 Essen · Germany

Tel.: +49 (0) 201/8 28-04

www.thyssenkrupp-foerdertechnik.com

Gea

rless

-driv

es |

e1 0

8201

1

For further information, please contact:

ThyssenKrupp Robins, Inc.6400 South Fiddler’s Green Circle, Suite 700Greenwood Village, Colorado 80111USA sales.tkri@thyssenkrupp.com www.thyssenkrupprobins.com

Siemens AG Industry Sector Industry Solutions Mining Technologies Schuhstr. 60 91052 Erlangen Germany mining@siemens.com www.siemens.com/mining

ThyssenKrupp Fördertechnik GmbHBusiness Unit MiningThyssenKrupp Allee 145143 EssenGermanyinfo@tk-mining.comwww.tk-mining.com

Belt

Conveyor

Coupling

CouplingBrake

Gear Box

Belt

Con

veyor

Brake

C-Converter

Transformer

Synch.Motor

C-Converter

Transformer

Synch.Motor

BeltDrivePulley

BeltDrivePulley

Our solution:Gearless Drives for conveyors – capable of handling high power requirements and easy to maintain

Together with Siemens, ThyssenKrupp has introduced a new high-performance generation of gearless, cycloconverter-fed conveyor drives. The principle has been proven for more than 25 years, with ongoing research and development. Its advantages are clear to see: fewer components, high availability, reduced overall energy consumption, lower maintenance costs.

Redefining power for conveyor drives

Long conveyors with high throughput and steep height differences require a significant amount of power. When the demand for power exceeds three MW per pulley, Gearless Drive systems are the right solution. This system overcomes the restrictions attributed to gear reducers, and its gearless construction is simple, robust and easy to maintain. Cycloconverter technology has proven its high reliability over several decades. Conveyor belt suppliers are also able now to manufacture stronger belts (ST-10,000) that can withstand higher stresses result-ing from higher drive power. In a word: The time to go gearless has come.

Fewer components, longer conveyor

Fewer high performance drives replacing many conventional ones: This formula makes longer conveyors more feasible and economical. With fewer components, the drive stations require smaller footprints. In underground applications, the number of expensive excavations are minimized.

Conventional drive system with fixed speed (left) and speed-

controlled Gearless Drive (right). By reducing mechanical

parts, maintenance costs can be significantly re duced: up

to 5 percent annually of the initial investment costs.

Good reasons for Gearless Drive Systems from Siemens and ThyssenKrupp |Compared to gear-reducer technology:

• Higher plant availability by eliminating electrical components, couplings, gearboxes, associated bearings and lubrication systems – therefore minimizing the risk of downtime

• Up to four percent higher energy efficiency achieved with gearless direct-drive technology

• Longer conveyors with fewer and smaller drive stations, resulting in reduced excavations in underground applications

• Higher power at the pulley – free from traditional gearbox limitations

• Reduce the potential for mechanical break-downs by using more robust components

• Fewer spare parts resulting in less inventory and lower capital investment

• Reduction of noise levels by eliminating the reducer, the loudest part of a conventional drive station In COOpERATIOn WITH SIEMEnS

Gearless Conveyor Drives Highest reliability, increased energy efficiency and low maintenance

ThyssenKrupp FördertechnikExcellence in Technology

rz_tk_GearlessDrive_brochure_USletter_GB.indd 1-3 01.09.11 10:29

The beginning: 1985 – the first conveyor using a gearless drive

In 1985, Siemens and ThyssenKrupp teamed up to install the world’s first gearless direct-drive belt conveyor with cycloconverter-fed synchronous motors. Engineers at RAG Deutsche Steinkohle were strongly persuaded by converter technology, and decided to apply it to the underground prosper-Haniel coal mine in Germany. More than a quarter-century later, the belt drives are still in operation – to the complete satisfaction of the customer. Management at RAG indicate that:

• There have been no significant interruptions or failures attributable to motors and converters

• Maintenance costs are significantly less than for belt drives with gearboxes

• Estimated savings of 10 percent on electrical energy are achieved annually compared to fixed speed geared conveyors.

The next generation: Going gearless in the peruvian Andes

Continuing their successful teamwork, ThyssenKrupp and Siemens are delivering Gearless Drives for Xstrata Copper’s new Antapaccay mine in peru. The drives will be operated at an elevation of 4,200 meters (13.780 feet). Two 3,800 kW (5,096 Hp), low-speed synchronous motors will provide 631 knm of torque to each drive pulley. The 1.37 meter wide belt will extend for 6,528 meters. The capacity of the conveyor is rated at 5,263 metric tons per hour, and it will operate at 6.2 meters per second. Using the well proven air-cooled cycloconverter will provide excellent behavior in this remote and mountainous area; specifically…

• When very high torque is needed; for example,

when restarting the conveyor at low speed

• In case one of the two drives goes down; operators then can continue using the system, empty the fully loaded belt and continue to operate the conveyor at a reduced rate.

SInAMICS SL 150 cycloconverter – air-cooled

• High overload capability

• Full converter power up to lowest motor speed (0 rpm)

• High efficiency through direct energy transformation (one step for AC/AC)

• Simple topology and few components result in: - robustness with high reliability - low investment costs - easy maintenance

• Low space requirement

• Long-established and proven converter technology

• Converter output frequency maximum 0.45 x fnet

SInAMICS SM 150 voltage source converter – water-cooled

• Latest converter technology

• Opportunity to regenerate for downhill operation and during breaking

• Excellent line impact - no reactive power is generated - low-line harmonics

• power compensation system is not needed

• Fast switching element (IGCT) results in high drive performance

• High efficiency as a result of high-voltage operation

• Converter power de-rating at very low output frequency < 2Hz

Your benefit:Move more ore. Save on energy. Save on maintenance costs.

Which converter to use?

Siemens offers two types of converters, each of which has its benefits. In Xstrata

Copper’s Antapaccay mine, the air cooled cycloconverter

SInAMICS SL 150 is used. The same converter is used for mill drives. Our engineers will

be glad to help you find the right solution for your mine.

In many mining areas, ore grades are declining. new mines are being developed in more remote areas, pits are getting deeper and underground mines are becoming larger. This means that more and more material must be transported over long distances and material handling poses new challenges. In order to achieve the increasing volumes and high demands for availability, conveying systems will need to implement the technologies made possible by today’s larger drive systems.

Can traditional drives stand up to 20,000 kW?

Drive configurations for large conveyors with gearboxes will reach their physical limits. For example a conveyor system with a drive power demand of more than 20,000 kW would require eight traditional drives, each of them equipped with 2,500 kW motors. Such a solution brings the disadvantage of reduced overall availability associated with a large number of mechanical components.

Maintenance in remote locations

The need for highly reliable equipment that can perform in remote mining regions is continually increasing. And at the same time maintenance costs need to be kept under control while production costs increase. Therefore, the need to use new technologies that reduce maintenance costs is an important factor when deciding on your future material handling solution.

You expect...

• Systems that help you transport more ore over longer distances

• High availability and minimized maintenance costs

• precise and powerful drive solutions

• Robust equipment, with fewer electrical and mechanical components

• Lower operating costs

• Optimized energy consumption

Your challenge:Remote locations, longer distances, higher throughput, difficult maintenance conditions

rz_tk_GearlessDrive_brochure_USletter_GB.indd 4-6 01.09.11 10:29

The beginning: 1985 – the first conveyor using a gearless drive

In 1985, Siemens and ThyssenKrupp teamed up to install the world’s first gearless direct-drive belt conveyor with cycloconverter-fed synchronous motors. Engineers at RAG Deutsche Steinkohle were strongly persuaded by converter technology, and decided to apply it to the underground prosper-Haniel coal mine in Germany. More than a quarter-century later, the belt drives are still in operation – to the complete satisfaction of the customer. Management at RAG indicate that:

• There have been no significant interruptions or failures attributable to motors and converters

• Maintenance costs are significantly less than for belt drives with gearboxes

• Estimated savings of 10 percent on electrical energy are achieved annually compared to fixed speed geared conveyors.

The next generation: Going gearless in the peruvian Andes

Continuing their successful teamwork, ThyssenKrupp and Siemens are delivering Gearless Drives for Xstrata Copper’s new Antapaccay mine in peru. The drives will be operated at an elevation of 4,200 meters (13.780 feet). Two 3,800 kW (5,096 Hp), low-speed synchronous motors will provide 631 knm of torque to each drive pulley. The 1.37 meter wide belt will extend for 6,528 meters. The capacity of the conveyor is rated at 5,263 metric tons per hour, and it will operate at 6.2 meters per second. Using the well proven air-cooled cycloconverter will provide excellent behavior in this remote and mountainous area; specifically…

• When very high torque is needed; for example,

when restarting the conveyor at low speed

• In case one of the two drives goes down; operators then can continue using the system, empty the fully loaded belt and continue to operate the conveyor at a reduced rate.

SInAMICS SL 150 cycloconverter – air-cooled

• High overload capability

• Full converter power up to lowest motor speed (0 rpm)

• High efficiency through direct energy transformation (one step for AC/AC)

• Simple topology and few components result in: - robustness with high reliability - low investment costs - easy maintenance

• Low space requirement

• Long-established and proven converter technology

• Converter output frequency maximum 0.45 x fnet

SInAMICS SM 150 voltage source converter – water-cooled

• Latest converter technology

• Opportunity to regenerate for downhill operation and during breaking

• Excellent line impact - no reactive power is generated - low-line harmonics

• power compensation system is not needed

• Fast switching element (IGCT) results in high drive performance

• High efficiency as a result of high-voltage operation

• Converter power de-rating at very low output frequency < 2Hz

Your benefit:Move more ore. Save on energy. Save on maintenance costs.

Which converter to use?

Siemens offers two types of converters, each of which has its benefits. In Xstrata

Copper’s Antapaccay mine, the air cooled cycloconverter

SInAMICS SL 150 is used. The same converter is used for mill drives. Our engineers will

be glad to help you find the right solution for your mine.

In many mining areas, ore grades are declining. new mines are being developed in more remote areas, pits are getting deeper and underground mines are becoming larger. This means that more and more material must be transported over long distances and material handling poses new challenges. In order to achieve the increasing volumes and high demands for availability, conveying systems will need to implement the technologies made possible by today’s larger drive systems.

Can traditional drives stand up to 20,000 kW?

Drive configurations for large conveyors with gearboxes will reach their physical limits. For example a conveyor system with a drive power demand of more than 20,000 kW would require eight traditional drives, each of them equipped with 2,500 kW motors. Such a solution brings the disadvantage of reduced overall availability associated with a large number of mechanical components.

Maintenance in remote locations

The need for highly reliable equipment that can perform in remote mining regions is continually increasing. And at the same time maintenance costs need to be kept under control while production costs increase. Therefore, the need to use new technologies that reduce maintenance costs is an important factor when deciding on your future material handling solution.

You expect...

• Systems that help you transport more ore over longer distances

• High availability and minimized maintenance costs

• precise and powerful drive solutions

• Robust equipment, with fewer electrical and mechanical components

• Lower operating costs

• Optimized energy consumption

Your challenge:Remote locations, longer distances, higher throughput, difficult maintenance conditions

rz_tk_GearlessDrive_brochure_USletter_GB.indd 4-6 01.09.11 10:29

ThyssenKrupp Fördertechnik GmbH

ThyssenKrupp Allee 1 · 45143 Essen · Germany

Tel.: +49 (0) 201/8 28-04

www.thyssenkrupp-foerdertechnik.com

Gea

rless

-driv

es |

e1 0

8201

1

For further information, please contact:

ThyssenKrupp Robins, Inc.6400 South Fiddler’s Green Circle, Suite 700Greenwood Village, Colorado 80111USA sales.tkri@thyssenkrupp.com www.thyssenkrupprobins.com

Siemens AG Industry Sector Industry Solutions Mining Technologies Schuhstr. 60 91052 Erlangen Germany mining@siemens.com www.siemens.com/mining

ThyssenKrupp Fördertechnik GmbHBusiness Unit MiningThyssenKrupp Allee 145143 EssenGermanyinfo@tk-mining.comwww.tk-mining.com

Belt

Conveyor

Coupling

CouplingBrake

Gear Box

Belt

Con

veyor

Brake

C-Converter

Transformer

Synch.Motor

C-Converter

Transformer

Synch.Motor

BeltDrivePulley

BeltDrivePulley

Our solution:Gearless Drives for conveyors – capable of handling high power requirements and easy to maintain

Together with Siemens, ThyssenKrupp has introduced a new high-performance generation of gearless, cycloconverter-fed conveyor drives. The principle has been proven for more than 25 years, with ongoing research and development. Its advantages are clear to see: fewer components, high availability, reduced overall energy consumption, lower maintenance costs.

Redefining power for conveyor drives

Long conveyors with high throughput and steep height differences require a significant amount of power. When the demand for power exceeds three MW per pulley, Gearless Drive systems are the right solution. This system overcomes the restrictions attributed to gear reducers, and its gearless construction is simple, robust and easy to maintain. Cycloconverter technology has proven its high reliability over several decades. Conveyor belt suppliers are also able now to manufacture stronger belts (ST-10,000) that can withstand higher stresses result-ing from higher drive power. In a word: The time to go gearless has come.

Fewer components, longer conveyor

Fewer high performance drives replacing many conventional ones: This formula makes longer conveyors more feasible and economical. With fewer components, the drive stations require smaller footprints. In underground applications, the number of expensive excavations are minimized.

Conventional drive system with fixed speed (left) and speed-

controlled Gearless Drive (right). By reducing mechanical

parts, maintenance costs can be significantly re duced: up

to 5 percent annually of the initial investment costs.

Good reasons for Gearless Drive Systems from Siemens and ThyssenKrupp |Compared to gear-reducer technology:

• Higher plant availability by eliminating electrical components, couplings, gearboxes, associated bearings and lubrication systems – therefore minimizing the risk of downtime

• Up to four percent higher energy efficiency achieved with gearless direct-drive technology

• Longer conveyors with fewer and smaller drive stations, resulting in reduced excavations in underground applications

• Higher power at the pulley – free from traditional gearbox limitations

• Reduce the potential for mechanical break-downs by using more robust components

• Fewer spare parts resulting in less inventory and lower capital investment

• Reduction of noise levels by eliminating the reducer, the loudest part of a conventional drive station In COOpERATIOn WITH SIEMEnS

Gearless Conveyor Drives Highest reliability, increased energy efficiency and low maintenance

ThyssenKrupp FördertechnikExcellence in Technology

rz_tk_GearlessDrive_brochure_USletter_GB.indd 1-3 01.09.11 10:29