Simine Con Gd En

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www.siemens.com/mining

Mining Technologies

SIMINE CON GDGearless Drive conveyor system in cooperation with ThyssenKrupp


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

In many mining regions, 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 longer distances, presenting new chal-

lenges for material handling systems.

In order to manage the increasing volumes and high de-

mands for availability, conveying systems will need to

implement the technologies made possible by todays

larger drive systems.

Can traditional drives withstand up to 20,000 kW?

In the near future, 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. This solution

carries the disadvantage of reduced overall availability as-

sociated 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 continuously increasing and

at the same time, maintenance costs need to be kept under

control as production costs grow. Therefore, the need touse 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

Precise and powerful drive solutions

Robust equipment, with fewer electrical and

mechanical components

High availability and minimized maintenance costs

Lower operating costs

Optimized energy consumption


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The beginning:

1985 the first conveyor using a gearless drive

In 1985, Siemens and ThyssenKrupp teamed up to install

the worlds 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 report that:

There have been no significant interruptions or failures

attributable to motors and converters.

Maintenance costs are significantly lower 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 a gearless drive for Xstrata

Coppers new Antapaccay mine in Peru. The drive 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 pro-

vide 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 motors goes down; operators

then can combine the cycloconverter and the gearless

drive for a period of time to provide twice the torque

on one pulley.

Which converter to use?

Siemens offers two types

of converters, each of

which has certain bene-

fits. In Xstrata Coppers

Antapaccay mine, the

air-cooled cycloconverter

SINAMICS SL 150 is used.

Our engineers will be

happy to help you findthe right solution for

your mine.

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


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SINAMICS SL 150 cycloconverter air-cooled

High overload capability

Full converter power up to lowest motor speed

(zero 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

The possibility to regenerate for downhill operation

and during braking

Low 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 derating at very low output

frequency < 2 Hz


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Our solution: Gearless Drives for conveyors capable of handling high power requirementsand easy to maintain

Good reasons forSIMINE CON GD

Compared to gear-reducer technology:

Higher plant availability

by eliminating electrical components, couplings,

bearings, and gearboxes 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, and reduced

excavations in underground applications

Higher power at the pulley

free from traditional gearbox limitations

Reduced maintenance needs

by reducing the potential for mechanical

breakdowns, and using robust components

Fewer spare parts

resulting in less inventory and less capital

investment

Reduction of noise level

by removing the reducer, the loudest component

in a conventional drive station

Conventional drive system (left) and speed-controlled gearlessdrive (right). By reducing mechanical parts, maintenance costscan be significantly reduced. Savings are estimated at up to fivepercent of the initial investment costs on an annual basis.

In collaboration with ThyssenKrupp, Siemens has intro-

duced a new high-performance generation of gearless,

cycloconverter-fed conveyor drives: SIMINE CON GD. 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 mining 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,

SIMINE CON GD is the right solution.

This system overcomes the restrictions attributed to gear re-

ducers, 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 to manufacture stronger belts (ST-10,000)

that can withstand higher stresses resulting from higher

drive power. In a word: The time to go gearless has come.

Fewer components, longer conveyors

Fewer high-performance drives replacing many conven-

tional ones: This formula makes longer conveyors a matter

of fact. With fewer components, the drive stations require

smaller footprints. In underground applications, the num-

ber of expensive cavities is minimized.

Belt

Conveyor

Coupling

CouplingBrake

Converter

Transformer

Asynch.Motor

Gearbox

BeltDrivePulley

Belt

Conveyor

Brake

C-Converter

Transformer

Synch.Motor

BeltDrivePulley


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All rights reserved.

SIMINE is trademark of Siemens AG.

The information provided in this brochure contains merely

general descriptions or characteristics of performance

which in actual case of use do not always apply as described

or which may change as a result of further development

of the products. An obligation to provide the respective

characteristics shall only exist if expressly agreed in the

terms of contract.

For further information,

please contact:

Siemens AG

Industry Sector

Industry Solutions

Mining Technologies

Schuhstr. 60

91052 Erlangen, Germany

E-Mail: [email protected]

Order No. E10001-M5-A40-V1-7600 | Printed in Germany |

Dispo No.: 21662 K No.: 28400 | GB 110790 WS 08111.0

08.2011, Siemens AG

Simine Con Gd En

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